Attachment_A_Specifications_EB_Lower_Guide_Bearing.docx

Statement of Specifications – RG EB PP Lower Guide Bearing

RG EB PP Lower Guide Bearing Statement of Work

Upper Colorado Basin Power Office Elephant Butte Field Division

Contents

1 Introduction The Elephant Butte Field Division (EBFD) Hydro-power Power Plant of the U.S. Bureau of Reclamation (USBR), Department of the Interior (DOI), has a need for a new, spare lower guide bearing (FIST Vol. 2-7, II. 2.2 & IV. 4.1). The following requirements and specifications define the Lower Guide Bearing to be supplied under this procurement.

2 Scope The contractor shall furnish one Lower Guide Bearing with babbitt finish, perform factory non-destructive testing, facilitate Contractor and Government quality control, and ship to EBFD freight on board with complete documentation for Operations & Maintenance.

3 General Requirements The Contractor shall fabricate, paint, inspect, and ship freight on board one generator lower guide bearing. This item is a spare and not to be installed. Including all hardware components required for a complete lower guide bearing assembly (stud bolts, nuts, and plugs for each bearing) in accordance with the Government furnished drawing and as specified in these specifications. The hardware is required to assemble the four pieces when Elephant Butte installs and assembles in place in the future. These specifications shall take precedence over the drawing. The Contractor shall duplicate the dimensions and features of the bearing depicted in Drawing No. 24-508-3599_EBFD_LOWER_GUIDE_BEARING_AS_BUILT.pdf (see Appendix A), with exception for the following alterations:

a. Dovetails shall not be used on the inner diameter of the bearing shell.

b. A textured surface shall be fabricated into the steel Inner Diameter of the bearing shell, to allow the babbitt to bond to the surface .

c. The final babbitt shall not exceed 3/8 inch.

3.1 Schedule of Work

A Schedule of Work including dates for inspections and repair work, shall be submitted within 14 calendar days from the date of contract award. The schedule shall be updated.

3.2 Dimensional Tolerances

3.2.1 Dimensional Tolerances for Structural Work

Dimensions shall be measured by a calibrated steel tape or calibrated micrometers of approximately the same temperature as the material at the time of measurement. The overall dimensions of an assembled structural unit shall be within the tolerances indicated on the drawings or as specified in the section pertaining to the specific item of work. For contract and reference drawings only, individual measurements shall not deviate from the dimensions shown on the drawings by more than 1/16-inch, unless otherwise specified.

3.2.2 Dimensional Tolerances for Machine Work

Tolerances, allowances, and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or to the dimensions shown on the contract drawings. Where fits are not shown, they shall be in accordance with good industrial practice for the intended application and approved prior to the beginning of work.

3.3 Drawings and Documentation Requirements

A. Submit drawings to include installation, manufacturing patterns, Bearing Details with Dovetail alteration listed and bonding method, and any other pertinent drawing data of the bearing for approval by the Government.

B. Provide casting specifications, including materials and ratings.

C. Provide storage and installation instructions to the government.

3.4 Materials

The classification and grade of material incorporated in the work shall be in accordance with the specifications designated herein, When two or more of these standards apply, the most stringent standard shall be used. All materials, parts, and components supplied shall be new and unused Test coupons shall be made available within 10 days of request.

Metals, equipment, and miscellaneous material shall conform to the requirements referred to in these specifications and when not specifically covered, metals and materials of standard quality shall be furnished.

Materials shall be of the classification and grades approved by the Contracting Officer. Products other than those specified herein may be accepted when it is proved to the satisfaction of the Government that they are equal in strength, durability, usefulness, and convenience for the purpose intended. In case the Contractor desires to use stock material not manufactured specifically for the work covered by these specifications, he shall submit evidence satisfactory to the Contracting Officer that such material conforms to the requirements of the specifications. Metals shall be free from scale, corrosion, and/or objectionable defects.

3.5 Fabrication

The Contractor shall have the option to choose the fabrication process used in making the lower guide bearing. The Contractor shall submit the Bearing Shell Fabrication Process at least 30 calendar days prior to fabrication.

3.5.1 Lower Guide Bearing Shell

3.5.1.1 Steel Forging

Steel forging shall have physical properties at least equal to those required by ASTM A 668/A 668M-S8, Class D, fully annealed and vacuum degassed, unless otherwise accepted.

3.5.1.2 Steel Casting

Castings shall not be warped or otherwise distorted, nor shall their dimensions be oversize to such extent as to interfere with proper fit and with other parts of the apparatus. The structure of the castings shall be homogeneous and free from excessive non-metallic inclusions. An excessive segregation of impurities or alloys at critical points in a casting will be cause for its rejection. Thickness and other dimensions of the castings as called for on the drawings shall not be reduced by shop or foundry practices. Except as otherwise approved or herein required, all steel castings shall conform to ASTM A 27/A 27M, Grade 70-40, or ASTM A 148/A 148M, Grade 80-40. Any casting patterns created in the process that may be used to produce additional bearings, shall be delivered along with the final bearing product.

3.5.1.3 Bolt Holes

Bolt holes shall be accurately located, smooth, and cylindrical. The work shall be done to ensure the interchangeability of parts. Holes for bolts shall have diameters of not more than 1/16-inch larger than bolt diameters, unless required by Contractor's design or contract or reference drawings. If the thickness of the material is not greater than the diameter of the bolts the holes may be punched. If the thickness of the material is greater than the diameter of the bolts, the holes may be drilled full size or sub-punched or sub-drilled at least 1/8-inch smaller than the diameter of the bolts and then reamed to full size. Poor matching of holes will be cause for rejection. Drifting occurring during assembly shall not distort the metal or enlarge the holes.

3.5.1.4 Non-Destructive Testing of Base Metal and Report

Perform visual (VT) and liquid penetrant (PT) inspection over the entire surface of each guide bearing prior to babbitting in accordance with applicable standards, ASME BPVC SEC VIII Appendix 8 and ASME BPVC SEC VIII, Appendix 12. All surfaces shall be examined using the liquid penetrant (PT) method. This shall be done using a solvent-removable visible dye and shall be in accordance with ASTM E 165. A certified written report by the independent party shall be prepared. The report shall set forth the UT procedures used, equipment used, a mapping of the areas tested and interpretation of results, specifically addressing lack of bonding or fusion, cracks, voids, and slag, the size and description of surface discontinuities and their accumulated total surface area relative to the inspected surface area, and the size and description of subsurface discontinuities. The report shall be prepared prior to further work on the area examined. The testing shall be witnessed, unless waived in writing.

3.5.1.5 Lower Guide Bearing Shell Pre-Babbitt Inspections

Measurements, checks, and NDT tests shall be performed by the Contractor and recorded on Contractor furnished inspection drawings and check sheets. Perform visual (VT) and either liquid penetrant (PT) inspection over the entire surface of each shell quarter prior to babbitting. If the bearing shell is fabricated, include final UT weld inspections. Measure surface finishes and dimensions. Map defect size and locations. The Contractor shall submit a Pre-Babbitt Inspection Report of findings and shall not proceed with babbitting until the report is approved by the Government.

3.5.1.6 Lower Guide Bearing Shell Post-Babbitt Inspections

Dimensional measurements, checks, and NDT tests shall be performed by the Contractor and recorded on Contractor furnished Inspection Sketches and Check Sheets that capture all bearing component dimensions, shapes, features, finishes, grooves, miscellaneous openings, threaded holes, plugs, inserts, keys, pockets, tolerances, fasteners, etc. and capture NDT findings. The finished turbine guide bearing shall be inspected while on the machining device with the four-quarters bolted together. The Contractor shall inspect the following:

A. With the stud bolts in place and torqued to manufacturer spec, and the assembled shell unrestrained, measure the babbitt bore diameter at three elevations: top, middle, and bottom. Take four measurements on 45-degree increments per elevation.

B. Measure the mounting flange OD, mounting flange thickness, bearing height, babbitted height.

C. Using feeler gauges, measure the O.D. and I.D. gap at the bearing split lines along the lines’ entire length. Record any gap 0.001 inch or larger listing width, length, and depth.

D. Any other measurements the manufacturer deems pertinent to the fit and specs.

3.5.2 Babbitting

The babbitt metal shall be new material conforming to ASTM B 23 Alloy. The tin used for tinning shall be 99 percent pure. Reclaimed metal shall not be used.

The Contractor shall submit a detailed step-by-step Tinning and Babbitting Procedure at least 30 calendar days prior to commencing the babbitting work. The Contractor shall not perform any babbitting until written approval of the procedure is received from the Government for both:

A. Tinning and Babbitting Procedure B. Pre-Babbitt NDT Inspection Results Babbitt shall be applied using the centrifugal spin cast method. NDT reports of castings or weldments in fabricated components shall be received and approved prior to babbitting.

3.5.3 Finishing & Painting

3.5.3.1 Finishes

Where surface finishes are indicated on the drawings or specified herein the symbols used or finished specified shall be in accordance with ASME B46.1. Values of roughness height specified are arithmetical average deviations expressed in micro inches. Roughness specified is the maximum value and any lesser degrees will be satisfactory unless otherwise called for on the drawing or in these specifications. Compliance with specified surface shall be determined by an electronic profilometer and by visual inspection of the work compared to Roughness Comparison Specimens, in accordance with the provisions of ASME B46.1. Values of roughness width and waviness height are not specified but shall be consistent with the general type of finish specified by roughness height. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable for the intended use will be cause for rejection.

Where the finish is not indicated or specified it shall be the most suitable for the surface, provide the class of fit required and shall be indicated on the shop drawings when machine finishing is provided by a symbol, which conforms, to ASME B46.1.

3.5.3.2 Painting

All painting shall be accomplished after babbitting, and the babbitted and finished machined surfaces shall not be exposed to abrasives or paints. Finished mating surfaces, top and bottom of the bolting flange, babbitted surfaces, the finished fits, threaded holes, and temperature detector holes shall not be painted. These surfaces and holes shall be thoroughly cleaned and coated with a suitable rust resistant compound. The coating shall be a minimum of 5 mils thick and shall be Zep Iron Clad or equivalent high-heat resistant, protective filming agent, providing corrosion protection for ferrous surfaces.

3.5.4 Substitutions and Deviations

Any substitution or deviation from these specifications shall be in the interest of the Government and specifically approved in writing by only the Contracting Officer.

3.6 Testing and Inspection Requirements

The Government reserves the right to inspect any or all phases of the work described in these specifications. The Government reserves the right to perform supplemental non-destructive examinations as deemed necessary when the soundness of any material or weldment is in doubt. The cost of such inspection will be borne by the Government. Any repairs and re-examination of repairs shall be performed by the Contractor, at no additional cost to the Government.

3.1 3.2 3.3 3.4 3.5 3.6

3.6.1 Methods and Procedures of Inspection

A. Manufacturer's methods and procedures of inspection, the evaluation of indications/defects and acceptance standards for indications/defects shall be prepared and submitted minimum of 30 days prior to fabrication. Methods and procedures shall conform to the applicable requirements of the ASME and AWS Codes. The more restrictive code requirements shall govern.

3.6.2 Non-Destructive Testing (NDT)

A. Weldments, shell material, and babbitt shall be subject to inspection to determine conformance with the requirements of ASME SECTION VIII and AWS Codes: AWS A2.4, AWS B2.1/B2.1M, AWS D1.1/D1.1M, AWS QC1, and provisions stated elsewhere in these specifications. An adequate inspection system shall be maintained as part of the Contractor's Quality Control Program and is subject to approval.

B. The Contractor shall notify the Government 21 days in advance of NDT, if the schedule has shifted from the initial submission under Schedule of Work, to provide time and planning for the Government Technical Representative (GTR) to be on-site for the NDT.

C. All NDT performed by the Contractor or subcontractor shall be witnessed by the Government, unless waived in writing or otherwise specified herein.

D. Written NDT inspection reports shall be submitted for all NDT inspections performed. Reports shall compare the “as-found” condition with the applicable standard.

E. Visual Examination (VT): Prior to the use of any material, it shall be thoroughly visually examined to determine suitability for use. Prior to welding, the preparation of material shall be visually inspected by the Contractor to assure compliance with the ASME code and AWS publications. During and after the welding, Contractor shall visually inspect for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement, contour and finish, bead reinforcement, and other surface defects to ensure compliance with the specification requirements.

F. Liquid Penetrant Inspection (PT): The Liquid Penetrant tests and inspections shall conform to the applicable requirements of Mandatory Appendix 8, Methods for Liquid Penetrant Examination (PT), of ASME BPVC SEC XIII D1. All defects disclosed by the test shall be repaired.

G. Ultrasonic Inspection (UT): The Contractor shall perform intermediate inspections and final inspections on material during and after fabrication. The UT testing shall conform to applicable requirements of Mandatory Appendix 12, Ultrasonic Examination of Welds, of ASME BPVC SEC VIII D1. All indications exceeding the acceptance standards permitted by Appendix 12 of the Code shall be repaired. A Certified UT Report shall be prepared, setting forth the procedures used, equipment used, mapping of tested areas and interpretation of results, specifically addressing any lack of bonding or fusion, cracks, voids, and slag, the size and description of surface discontinuities and their accumulated total surface area relative to the inspected surface area, and the size and description of subsurface discontinuities. The testing shall be witnessed, unless waived in writing.

H. Metallic Casting Examination: The examination and acceptance criteria for metallic castings when using MT, PT, or UT shall be in accordance with Mandatory Appendix 7, Examination of Steel Castings, of ASME BPVC SEC VIII D1.

3.7 Welder(s) and Welding

3.7

3.7.1 Welder(s) Record of Qualification

A. Welders shall be qualified for the type of work to be done. Qualification shall be in accordance with whichever of the following is most applicable to the work being performed; AWS D1.1/D1.1M (Section 4C) or ASME Boiler and Pressure Vessel Code (ASME BPVC SEC IX) or AWS B2.1/B2.1M.

B. The Contractor shall certify by name the welders so qualified including the date of qualification, code, and procedures under which qualified.

C. The Record of Qualification of Welder(s) shall be submitted for approval, by the Contractor to the Government.

3.7.2 Welding Operations

A. Preparation and Procedure for welded joints under hydrostatic or hydraulic pressure shall meet the requirements stated in ASME BPVC SEC IX.

B. Test Coupons The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by non-destructive inspection. Coupons will be subjected to a guided bend test. When coupons are removed from any part of a structure, the members cut shall be repaired with joints which conform to ASME BPVC SEC IX or AWS D1.1/D1.1M, with peening as approved or directed to relieve residual stress.

C. Protection of Finished Work Surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means. Finished surfaces of ferrous metal to be in bolted contact shall be washed with a rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping, and storage periods. Finished surfaces of metals which will be exposed after installation shall be coated with paint.

4 References This Section shall apply to both weldments, materials, and processes, as applicable. The publications and references listed below form a part of this specification only to the extent referenced.

A. ASME INTERNATIONAL (ASME)

a. ASME BPVC SEC VIII D1 (2011) Section VIII Division 1 Rules for Construction of Pressure Vessels- Includes 2011 Addenda

b. ASME BPVC SEC IX (2011) Qualification Standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators.

B. ASTM INTERNATIONAL (ASTM)

a. ASTM A 27/A 27M (2008) Standard Specification for Steel Castings, Carbon, for General Application

b. ASTM A 148/a 148M (2008) Standard Specification for Steel Castings, High Strength, for Structural Purposes

c. ASTM A 307 (2004) Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength

d. ASTM A 516/A 516M (2004) Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-Temperature Service

e. ASTM 668/A 668M (2004) Steel Forgings, Carbon and Alloy, for General Industrial Use

f. ASTM B 21/B (2001e1) Naval Brass Rod, Bar, and Shapes

g. ASTM B 23 (2000; R 2010) White Metal Bearing Alloys

h. ASTM E 114 (2010) Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method

i. ASTM E 165 (2012) Liquid Penetrant Inspection Method

j. ASTM F 436 (2009) Hardened Steel Washers

k. ASTM A380 (2006) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

l. ASTM A36/A36M (2008) Standard Specification for Carbon Structural Steel

C. AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

a. ASNT SNT-TC-1A (2006; Supp 2010) Recommended Practice No. SNT-TC-1A: Personnel Qualification and Certification in Nondestructive Testing and ANSI/ASNT CP-105: Training Outlines for Qualification of Nondestructive Testing Personnel

D. AMERICAN WELDING SOCIETY (AWS)

a. AWS A2.4 (2007) Standard Symbols for Welding, Brazing and Nondestructive Examination

b. AWS B2.1/B2.1M (2009) Specification for Welding Procedure and Performance Qualification

c. AWS D1.1/D1.1M (2010) Structural Welding Code – Steel

d. AWS QC1 (2007) Standard for AWS Certification of Welding Inspectors3.5.2 Non-Destructive Testing (NDT)

E. THE SOCIETY FOR PROTECTIVE COATINGS (SSPC)

a. SSPC Paint 36 (2006) Two component Weatherable Aliphatic Polyurethane Topcoat, Performance Based

b. SSPC Paint 40 (2007) Zinc Rich Moisture Cure Polyurethane Primer, Performance Based

c. SSPC SP 6/NACE No. 3 (2007) Commercial Blast Cleaning

5 Submittals - Table of Items from Section 6

6 Submittals

6.1 Drawings

Fabrication Drawings for Lower Guide Bearing with specifications, including steel casing surface change, dovetail alteration, and new bonding method; shall be submitted for written Government approval at least 30 days prior to commencing work.

As-Built Drawings, Shop casting and Pattern drawings, as applicable; Assembly drawings, and the type of oils required to lubricate the stud bolts during assembly shall be submitted with the Final Inspection Report and shall be included in the packaging for shipment.

6.2 Schedule of Work

Submit within 14 calendar days from the date of contract award and updated whenever there are changes.

6.3 Product Data

Specification of Materials for steel fabrication or casting and babbitt shall be submitted 14 days prior to using materials.

Rust Resisting Compound and Paint for Protective Coating specifications shall be submitted at least 14 days prior to use.

6.4 Inspection and Test

6.1 6.2 6.3 6.4

6.4.1 Inspection and Test Schedule

Submit within 14 calendar days from the date of contract award and updated whenever there are changes.

6.4.1.1 Lower Guide Bearing Shell Pre-Babbitt Inspections

The Contractor shall submit a Pre-Babbitt Inspection Report of findings and shall not proceed with babbitting until the report is approved by the Government.

6.4.1.2 Lower Guide Bearing Shell Post-Babbitt Inspections

NDT tests results shall be submitting within 5 calendar days of completing the Post-Babbitt NDT Inspection.

6.4.2 Manufacturer’s Methods and Procedures of Inspection

Submitted minimum of 30 days prior to fabrication.

6.4.3 NDT Inspection Reports (including Visual Examination, Liquid Penetrant Inspection, Ultrasonic Inspection, and Metallic Casting Examination) NDT reports of castings or weldments in fabricated components shall be received and approved prior to babbitting.

NDT reports for Final Inspection Report shall include everything required in the previous NDT reports and all final witnessed measurements, inspections, babbitt analysis, and miscellaneous checks, within 5 calendar days of completing the final inspection. The final report shall be accepted prior to shipment of the bearing, unless otherwise directed. A copy of the final inspection report shall be placed inside the packaging for shipment.

6.5 Records of Qualifications

6.1 6.2 6.3 6.4 6.5

6.5.1 Record of Qualification of Welder(s)

Minimum of 30 calendar days prior to Contractor’s performance of work.

6.5.2 Record of Qualification of Ultrasonic Inspection

Minimum of 30 calendar days prior to Contractor’s performance of work.

6.6 Manufacturer’s Storage, Maintenance, and Installation Instructions Shall be submitted prior to Contractor’s Final Acceptance and a copy shall be submitted with Bearing packing list.

6.7 Manufacturer’s Fabrication and Babbitting Processes

6.7.1 Bearing Shell Fabrication Process

Minimum of 30 calendar days prior to fabrication for Government Approval.

6.7.2 Tinning and Babbitting Procedure

Minimum of 30 calendar days prior to fabrication for Government Approval.

7 Packaging, Marking, and Shipping

7.1 Packaging

Packaging for the furnished bearing shall be provided by the Contractor. Packaging shall prevent deterioration and damages due to the hazards of shipping, storage, handling, and processing. Each shell segment shall be packed within an individual compartment in the packing crate for shipment. The packaging shall be for long-term storage and include coating all components with an accepted rust preventative substance as specified. The method of packing shall be suitable for handling with a crane and lift truck. All packaging materials used shall become the property of the Government. The Contractor shall prepare and load the bearing segments for shipment in such a manner as to protect them from damage in transit and shall be responsible for and make good any and all damages until they are delivered to the Government at the specified delivery point. After satisfactory inspection, all surfaces shall be coated with a protective filming agent which is suitable to withstand shipping and long-term storage of at least 10 years. Submit product data for the Rust Resisting Compound chosen by the Contractor at least 30 calendar days prior to use. All holes, inlets and outlets shall be cleaned and covered to exclude dirt, water, etc.

7.2 Marking

The Contractor shall stamp their name, contract date, and the Government contract number on the side of each bearing segment, along with a bearing shell identification number. The packaging shall be clearly labeled with the return address and package contents.

7.3 Shipping

The bearing shall not be shipped until it has been inspected and accepted for shipment by the Government, or unless inspection has been waived in writing. The Contractor shall be liable for any loss or damage incurred during handling, shipping, storage, and shop processing. Procedures for the repair of any damage incurred in this process shall be subject to the Government's approval.

The specified delivery point is:

Elephant Butte Field Division

4696 HWY-51

Truth or Consequences, NM 87901 8 Final Inspection and Acceptance Final Inspection and Acceptance for full compliance with the specifications will be made by the Government upon delivery to the project site. Tests may be repeated at the project site to ensure materials and workmanship conform to the specifications. Tests will be at the Contractor’s expense if the components do not meet contract requirements. The Contractor will be notified in writing of acceptance only by the Contract Officer. The date of this notification is the starting date of the warranty period.

9 Warranty Warranty provisions of these specifications shall apply to any furnished part, except that notwithstanding inspection and acceptance, the finished components shall be warranted to conform to these specifications for three years after receipt and acceptance at delivery site or 8000 hours of unit operation after installation, whichever comes first.

10 Appendix A – As-Built Drawing of Lower Guide Bearing Drawing A - 24-508-3599_EBFD_LOWER_GUIDE_BEARING_AS_BUILT.pdf

Submittal Instructions:

1. Prospective bidders shall provide information, including contact information, regarding past performance of the bidder for previous, similar jobs of refurbishing babbitt bearings projectsused in industrial or utility facilities.

2. Itemized costs shall be furnished for the needed items.

3. Lead time for delivery after receipt of award.

4. Proposals shall include detailed data sheet of product provided.

5. Manufacturer warranty with stated terms shall be included in proposal.

If the vendor does not include the above information with their quote the quote can be found nonresponsive.

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