BC Runner Sources Sought Specs DRAFT_1.pdf

DRAFT

Black Canyon Powerplant

U1 and U2 Hydro Pump - Turbine Runner Replacement

Boise Project, Idaho Specifications No. 140R1021R00xx

Hydraulic Design

48 13 01-1

SECTION 48 13 01

HYDRAULIC DESIGN

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Hydraulic Design:

1. Payment: Lump sum price offered in Price Schedule A – Unit 1.

a. Including:

1) Hydraulic design, computational fluid dynamics analysis and report.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME)

1. ASME PTC18-11 Power Test Code for Hydraulic Prime Movers

1.03 DEFINITIONS

A. CFD: Computational Fluid Dynamics

B. CFS: Cubic feet per second.

C. EL.: Elevation in feet above mean sea level.

D. PSI: Pounds per square inch.

E. Q: Penstock rate of flow in cubic feet per second (cfs).

F. RPM: Revolutions per minute.

1.04 SYSTEM DESCRIPTION

A. General:

1. To provide a hydraulic design for new Francis turbine runners that has been optimized to meet the specified operating characteristics using CFD.

1.05 OPERATIONAL INFORMATION

A. Hydro pump units: Two hydraulic turbine driven pumps for irrigation.

B. Operate April 1 to October 31 for irrigation.

48 13 01-2

C. Turbine Information:

1. The unit original design speed is 380 rpm, clockwise, viewed from above.

2. Unit runaway speed: 450 rpm.

3. Operational speeds vary to improve pump efficiency based on flowrate requirements.

4. Rated head: 89 feet.

5. Rated power: 1,110 horsepower.

6. Continuous operations between 30 to 100-percent wicket gate opening.

7. Unit Cycles:

a. Number of starts/stops per day: 2

b. Runaway: 4 times per year.

8. Wicket Gate Mechanism:

a. Wicket gates are motor operated to opened or closed.

b. Shift Ring Travel: 3.25-inches from full open to full closed.

c. Smallest opening (ball opening) between two wicket gates at 100-percent gate opening: 3.5-inches.

d. Change of servomotor stroke not acceptable.

e. Normal Timing: 2 minutes for full open to close.

D. Pump Information:

1. Rated head: 28.5 feet.

2. Rated power: 523 horsepower.

3. Rated flowrate: 163 cfs

4. Minimum pump flowrate: 50 cfs

1.06 HYDRAULIC INFORMATION

A. Turbine water operating temperature: 50 to 60 degrees F.

B. Majority of the operational season the headwater elevation is maintained between 2497 and 2498 feet.

C. Turbine and Reservoir Operating Conditions in feet. Refer to Table 1.

48 13 01-3

Table 1: Operating Conditions

Tailwater EL.

Minimum 2403

Normal 2404

Maximum 2407

Headwater

Minimum for generation 2485

Normal range 2497 to 2498

Maximum 2498

Distributor Centerline 2417.08

1.07 TURBINE INFORMATION

A. Original Manufacturer: Worthington Pump and Machinery Works

B. Type: Vertical Francis

C. Component Weights:

1. Runner: 900 pounds.

2. Impeller: 1,350 pounds.

3. Turbine Shaft: 2,000 pounds.

D. Rotating Wear Rings:

1. Upper Wear Ring outer diameter: 29.000-inches, +0 – 0.003-inches.

2. Lower Wear Ring outer diameter: 32.125-inches, +0 – 0.003-inches.

E. Kingsbury Thrust Bearing:

1. 10.5-inches, 3 shoes.

2. Weight of turbine parts, including hydraulic thrust at twice runner design wearing ring clearance, to be carried by the thrust bearing: 10,500 pounds.

48 13 01-4

F. The Government will laser scan the existing runner and wicket gates. The informational file will be provided after award.

G. Provide inner diameter design requirements for stationary wear rings.

H. The Government will conduct performance testing on the prototype runners in accordance to ASTM PTC 18 within two years of the unit placed into Commercial

Operation.

1.08 SUBMITTALS

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

B. RSN 48 13 01-1, CFD Results:

1. Results of CFD studies at net heads of 80, 89 and 95 feet:

a. Representation of the velocity and pressure distribution across the runner blades and wicket gates.

b. Potential areas of cavitation.

c. Operational speed, 110% speed, and runaway.

d. Potential operational issues between 30 to 100-percent wicket gate opening provide a description and detailed views clarifying the issues.

e. Software used, boundary conditions, mesh density, number of nodes, and load applications.

C. RSN 48 13 01-2, Performance Results:

1. Sufficient data to encompass operating conditions over the full range of net heads, reservoir and tailwater elevations and gate openings unless otherwise specified.

2. Complete prototype hill chart:

a. The entire range of operation from speed-no-load to full gate.

b. Normal and maximum rotational speed, without damaging cavitation, limits identified, and not to exceed runaway.

c. Potentially restricted operation indicated.

d. Expected incipient inlet edge cavitation conditions noted.

e. Expected incipient outlet edge cavitation conditions noted over tailwater elevations range.

3. Derived performance curves for the prototype runner with the following criteria:

a. Net heads of 80, 89, and 95-feet showing efficiency, gate opening in percent and discharge in cubic feet per second with reference to horsepower output.

48 13 01-5

b. Curves showing permissible gate openings for tailwater minimum, normal and maximum elevations.

4. Maximum servomotor stroke corresponding to 100 percent wicket gate opening.

5. Maximum downward-thrust:

a. With runner design wear ring clearance.

b. With twice the runner design wearing ring clearance.

6. Maximum up-thrust:

a. With runner design wear ring clearance.

b. With twice the runner design wear ring clearance.

7. Maximum sustained full gate runaway speed at 95 feet of net head.

1.09 PACKAGING

A. Refer to Section 01 60 00 – Product Requirements.

1.10 DELIVERY, STORAGE AND HANDLING

A. Refer to Section 01 60 00 – Product Requirements.

PART 2 PRODUCTS

2.01 DESIGN AND PERFORMANCE REQUIREMENTS

A. Operational limits for the water-surface elevations for reservoir and tailwater.

B. Not to exceed the maximum hydraulic down-thrust at twice design clearances.

C. Not to exceed existing runaway speed during a sustained or transient runaway situation with gates at full open and maximum net head on the turbine.

D. Varying operational speeds to allow for efficient pump operations between 50 cfs and

163 cfs per unit.

E. Efficiency curves shall be free of dips and valleys.

F. Runner operation from 30 to 100-percent wicket gate opening over the effective net head range on the turbine is between 80 and 95 feet.

G. Units to be designed to operate continuously at all conditions within the guaranteed cavitation free operating range.

H. No limitation due to cavitation for one-unit output from 80 to 95 feet net head, from 30 percent gate to maximum output, and with varying operational speeds.

48 13 01-6

I. Provide holes through the crown for hydraulic balance as necessary.

2.02 CFD ANALYSIS

A. Specific, graphic representation of flow and pressure fields to prove hydraulic design suitability:

1. Pressure distribution:

a. Cavitation on pressure charts.

b. Pressure pulsations from flow instability.

2. Velocity distribution.

3. Flow profiles:

a. Stable and unstable flow conditions.

PART 3 EXECUTION

Not Used.

END OF SECTION

U1 and U2 Hydro Pump - Turbine Runner Replacement

Boise Project, Idaho Specifications No. 140R1021R00xx

General Testing Methods

48 13 03 -1

SECTION 48 13 03

GENERAL TESTING METHODS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Include in the Prices offered in the Price Schedules for other items of work.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME)

1. ASME BPVC-V-2019 Boiler and Pressure Vessel Code - Section V

- Nondestructive Testing

B. American Society for Nondestructive Testing (ASNT)

1. ASNT SNT-TC-1A-2006 Personal Qualification and Certification in

Nondestructive Testing

C. ASTM International

1. ASTM A609/A609M-18 Castings, Carbon, Low-Allow, and

Martensitic Stainless Steel, Ultrasonic

Examination Theory

2. ASTM A802/A802M-19 Steel Castings, Surface Acceptance

Standards, Visual Examination

3. ASTM A903/A903M-17 Standard Specification for Steel Castings, Surface Acceptance Standards, Magnetic

Particle and Liquid Penetrant Inspection

4. ASTM E165-18 Liquid Penetrant Examination for General

Industry

5. ASTM E709-15 Magnetic Particle Testing

6. ASTM E1742/E1742M-18 Radiographic Examination

D. Cahier Des Charge (CCH)

1. CCH 70-4 Inspection of Steel Castings of Hydraulic

Machines

1.03 DEFINITIONS

A. NDE: Non-Destructive Examination.

General Testing Methods

48 13 03 -2

B. PT: Dye-Penetrant Examination.

C. UT: Ultrasonic Examination.

D. VT: Visual Inspection.

E. MT: Magnetic Particle Examination.

F. RT: Radiographic Examination.

1.04 QUALIFICATIONS

A. Non-Destructive Examination Personnel:

1. Qualified in accordance with applicable method of the ASNT SNT-TC-1A or

ASME BPVC-V.

2. Qualification minimum for VT, PT and MT: Level II or higher.

3. Qualification minimum for UT: Level III.

4. Qualification minimum for RT: Level III.

1.05 NON-DESTRUCTIVE TESTING

A. Application of NDE reference standard is dependent on product type, location and operation.

B. VT, MT, and PT Testing:

1. VT shall be in accordance with ASTM A802 or ASME BPVC-V.

2. MT shall be in accordance with ASTM E709 or ASME BPVC-V.

3. PT shall be in accordance of ASTM E165 or ASME BPVC-V.

4. Acceptance Criteria for VT, MT, and PT testing shall be in accordance with

ASTM A802, Level 1 for all surfaces, as approved by Government.

5. Report all defects with clear defect mapping (location), defect size and depth.

C. UT Testing:

1. UT volumetric inspection in accordance with ASTM A609, ASME BPVC-V, or

CCH 70.

2. Acceptance Criteria for UT testing shall be in accordance ASTM A609, Quality

Level 1, or CCH 70, as approved by Government. Parts not meeting that acceptance criteria are rejected.

3. Report all defects with clear defect mapping (location), defect size and depth.

D. RT Testing:

48 13 03 -3

1. RT volumetric inspection in accordance with ASTM E1742, ASME BPVC-V, or

CCH 70.

2. Acceptance Criteria: Per CCH 70. Parts not meeting acceptance criteria are rejected.

E. Reporting:

1. Report all defects with clear defect mapping (location), defect size and depth.

2. When possible, provide color photos of defects with scale for relative size.

1.06 PROOF LOAD TESTING

A. Perform one proof load test per material batch and/or heat of each stud type. Develop the stress-strain curve with the values for proof load, yield stress and ultimate tensile stress.

B. From each material batch/heat, supply at minimum an additional two (2) studs for each type of stud for the destructive test to establish proof load. Supply additional studs to ensure compliance with the design requirements is achieved.

PART 2 EXECUTION

Not Used.

48 13 03 -4

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U1 and U2 Hydro Pump - Turbine Runner Replacement

Boise Project, Idaho Specifications No. 140R1021R00xx

Critical Connection Fasteners

48 13 09 - 1

SECTION 48 13 09

CRITICAL CONNECTION FASTENERS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Critical Connection Fasteners:

1. Payment: Lump-sum price offered in the Price Schedules A – Unit 1 and Unit 2.

a. Includes:

1) Thrust Nut.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME)

1. ASME B1.1-2019 Unified Inch Screw Threads, (UN and UNR Thread

Form)

B. ASTM International

1. ASTM A 194/A 194M-20 Carbon and Alloy Steel Nuts for Bolts for High

Pressure or High Temperature Service, or Both

1.03 DEFINITIONS

A. See Specification Section 48 13 03 – General Testing Methods.

1.04 SYSTEM DESCRIPTION

A. General:

1. This Section describes critical fasteners to by designed and furnished by the

Contractor and supplied to the Government for installation by the Government.

Contractor to supply test quantities as required to meet contract requirements.

2. Design thrust nut to fit within existing bearing cover or provide cover modification drawings to allow for additional height. Design approval by COR.

1.05 SUBMITTALS

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

B. RSN 48 13 09-01, Approval Documentation:

1. Manufacturing and Detail Drawings.

2. Commercial Products:

Critical Connection Fasteners

48 13 09 - 2

a. Cut sheets for purchased studs and nuts.

b. Including manufacturer information.

3. Material certification for each component and from each material batch and/or heat (if more than one batch/heat).

4. Include chemical composition, material strengths, hardness (if applicable) and percent elongation.

5. Heat treatment records for each heat or batch.

6. Design for multi-jack tensioning system.

7. Provide installation procedure and torque values.

C. RSN 48 13 09-02, Final Documentation:

1. NDE reports.

2. Final Inspection sheets, dimensional and geometrical inspections.

3. As-Built Drawings

4. Provide the stress-strain curve with the values for proof load, yield stress and ultimate tensile stress.

1.06 QUALIFICATIONS

A. Non-Destructive Examination:

1. See Specification Section 48 13 03 – General Testing Methods.

1.07 PACKAGING

A. Refer to Section 01 60 00 – Product Requirements.

1.08 DELIVERY, STORAGE AND HANDLING

A. Refer to Section 01 60 00 – Product Requirements.

PART 2 PRODUCTS

2.01 PRODUCT DESCRIPTIONS

A. Quantity Requirements:

1. Furnish 1 new turbine shaft thrust nut per unit.

B. Manufacturing Requirements:

1. Threads shall be in accordance with ASME B1.1.

2. Thrust Nut:

48 13 09 - 3

a. Reference: Refer to drawing titled Thrust and Upper Guide Rotating

Components.

b. Thread Inner Diameter: 2.850-inches, confirm with COR.

c. Multi-jack bolting design for adequate preload.

d. Design height to fit within bearing cover or provide redesign drawings for cover modifications, approval by COR.

C. Mechanical Locking:

1. Provide mechanical locking design for:

a. Thrust Nuts: locking wire for jacking bolts.

2. Weld locks are not permitted.

D. Drawings Requirements:

1. Refer to Section 01 33 00 - Submittals

2. Section 01 60 00 – Product Requirements

2.02 MATERIALS

A. Nuts: ASTM A194, 2H.

2.03 NON-DESTRUCTIVE TESTING

A. See Specification Section 48 13 03 – General Testing Methods.

B. VT, MT, and PT Testing:

1. Perform 100 percent VT.

2. Perform 100 percent MT or 100 percent PT.

PART 3 EXECUTION

A. Not Used

48 13 09 - 4

U1 and U2 Hydro Pump - Turbine Runner Replacement

Boise Project, Idaho Specifications No. 140R1021R00xx

Vertical Hydro Pump Runner

48 13 10-1

SECTION 48 13 10

VERTICAL FRANCIS TURBINE RUNNER

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Vertical Francis Turbine Runner:

1. Payment: Lump-sum price offered in the Price Schedules A – Unit 1 and Unit 2.

a. Includes:

1) Stainless-steel Francis type turbine runners with integral rotating wearing rings and nose cones per unit.

2) Appurtenant components and hardware required for new runner design per unit.

3) Finite element analysis and report.

4) Inlet and outlet blade templates.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME)

1. ASME BPVC-VIII-2019 Boiler and Pressure Vessel Code - Section VIII -

Rules for Construction of Pressure Vessels Division

2. ASME BPVC-IX-2019 Boiler and Pressure Vessel Code - Section IX -

Welding and Brazing Qualifications

3. ASME B1.1-2019 Unified Inch Screw Threads, UN and UNR Thread

Form

4. ASME B4.1-2009 Preferred Limits and Fits for Cylindrical Parts

5. ASME B46.1-2009 Surface Texture (Surface Roughness, Waviness and

Lay)

6. ASME PTC18-11 Power Test Code for Hydraulic Prime Movers

B. American Society for Nondestructive Testing (ASNT)

1. ASNT SNT-TC-1A-2006 Personnel Qualification and Certification in

Nondestructive Testing

C. ASTM International (ASTM)

Vertical Hydro Pump Runner

48 13 10-2

1. ASTM A182/A182M-20 Forged or Rolled Alloy and Stainless Steel Pipe

Flanges, Forged Fittings, and Valves and Parts for

High-Temperature Service

2. ASTM A193/A193M-20 Alloy-Steel and Stainless-Steel Bolting Materials for High Temperature Service

3. ASTM A240/A240M-20 Chromium and Chromium-Nickel Stainless Steel

Plate, Sheet and Strip for Pressure Vessels

4. ASTM A380/A380M-17 Cleaning, Descaling, and Passivation of Stainless

Steel Parts, Equipment, and Systems

5. ASTM A743/A743M-19 Castings, Iron Chromium, Iron-Chromium-Nickel

Corrosion Resistant for General Applications

6. ASTM A903/A903M-17 Steel Castings, Surface Acceptance Standards, Magnetic Particle and Liquid Penetrant Inspection

7. ASTM A967/A967M-17 Chemical Passivation Treatments for Stainless Steel

Parts

D. American Welding Society (AWS)

1. AWS D1.6/D1.6M:2017 Structural Welding Code – Stainless Steel

E. International Electrotechnical Commission (IEC)

1. IEC 60193:2019 Hydraulic Turbines, Storage pumps and Pump-

Turbines Model Acceptance Tests

F. International Organization of Standardization (ISO)

1. ISO 1940/1-2003 Mechanical Vibration – Balance Quality

1.03 DEFINITIONS

A. See Specification Section 48 13 03 – General Testing Methods.

B. FEA: Finite Element Analysis.

1.04 SYSTEM DESCRIPTION

A. General:

1. This Section describes the runner, nose cone and appurtenant parts to by designed and furnished to the Government for installation by the Government.

1.05 SUBMITTALS

A. Submit in accordance with Section 01 33 00 – Submittals:

B. RSN 48 13 10-1, Runner Mechanical Analysis:

48 13 10-3

1. Stress and Fatigue Life Calculations.

a. Provide complete information used in the design and calculations.

b. Furnish design calculations and complete information as to the maximum stresses used in the design.

2. FEA of runner.

3. Analysis of the natural frequencies of the runner and the passing frequency interaction of the wicket gates and stay vanes. Provide sufficient margins between natural frequencies and exciting frequencies, not less than plus or minus 20 percent.

C. RSN 48 13 10-2, Design Data and Drawings:

1. Design Data:

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

2. Manufacturing and detail drawings.

a. Runner Assembly and Fabrication

1) Include weight of the runner and cone.

3. Inlet and outlet blade edge template drawings and drawings showing positioning of the templates for reference.

4. Wear ring diameter requirements per approved design.

5. Inspection Test Plan:

a. Nondestructive examination methods for locating casting defects and weld defects of the runner components and fabricated runner.

b. Heat treatment procedure.

c. Runner balancing procedure.

6. Manufacturing and fabrication schedule.

D. RSN 48 13 10-3, Material Certification:

1. Commercial Products: Cut sheets for purchased studs and nuts, if required for runner design. Including manufacturer information.

2. Material certification for each component and from each material batch and/or heat (if more than one batch/heat).

3. Include ladle analysis consisting of chemical composition, material strengths, hardness (if applicable) and percent elongation.

4. Heat treatment records for each heat or batch.

E. RSN 48 13 10-4, Inspection Reports:

1. NDE reports including Personnel Qualification Records per ASTM A903 S1.

48 13 10-4

2. Reports of NDE and dimensional checks of blades, crown, and band, including casting defect mapping and extent of defect excavation prior to repair welding.

a. Government approval is required for welding of major defects, prior to repair.

3. Homology reports after final machining.

4. Casting and fabrication shop locations.

F. RSN 48 13 10-5, Final Runner Report:

1. Results of final turbine runner balance.

a. Include on as-built drawings.

2. Final machining dimensional check sheet including final homology.

a. Material and ambient temperature when measurements were taken.

3. Final as-built drawings.

4. Drawings reflecting non-conformance dimensions or unit specific dimensions:

a. Dimensions specific to an individual unit, appropriately label.

b. Final machined weight.

1.06 QUALIFICATIONS

A. Non-Destructive Examination:

1. See Specification Section 48 13 03 – General Testing Methods.

B. Welding Procedures and Welding Operators:

1. Welding of principle stress-carrying parts: ASME BPVC-IX.

2. Welding of low stress parts: ASME BPVC-IX.

1.07 PACKAGING

A. Refer to Section 01 60 00 – Product Requirements.

1.08 DELIVERY, STORAGE AND HANDLING

A. Refer to Section 01 60 00 – Product Requirements.

B. All submittals must be received and approved prior to the shipment of the runner.

C. Take every precaution during loading, transportation, unloading, and storage to prevent damage to the turbine runner and associated equipment. Repair damage to the turbine runners and associated equipment as directed if, in the opinion of the Government, a satisfactory repair can be made; otherwise replace damaged components and associated equipment.

48 13 10-5

D. Protect from corrosion, deformation and other types of damage.

E. Deliver the turbine runners and associated equipment to the location as directed by the

Government.

F. Store the turbine runners and associated equipment and perform required maintenance during storage until ready for delivery to Government.

1.09 SPECIAL TOOLS

A. Gauges, tooling and appurtenances, and other records:

1. Special gauges, tooling and appurtenances necessary for field erection will become the property of the Government.

a. Deliver to Government with runner completion or shipment.

PART 2 PRODUCTS

2.01 PRODUCT DESCRIPTIONS

A. Quantity Requirements:

1. Furnish one (1) new runner and nose cone per unit.

2. Furnish one (1) set of templates.

B. Stress Calculations:

1. See Specification Section 48 13 01 – Hydraulic Design.

2. See Specification Section 48 13 02 – General Mechanical Evaluations.

3. Provide FEA and analytical stress analysis on the runner.

C. Fatigue Life Calculations:

1. See Specification Section 48 13 02 – General Mechanical Evaluations.

2. Provide fatigue life analysis on the runner.

D. Drawing Requirements:

1. Refer to Section 01 33 00 - Submittals

2. Section 01 60 00 – Product Requirements

E. Threads shall be in accordance with ASME B1.1.

F. Runner Design Requirements:

1. Refer to Section 48 13 01 –Hydraulic Design, for hydraulic design requirements and unit operation.

48 13 10-6

2. Refer to Section 52 00 00 – Drawings.

3. Design runner from separate band, crown, and blades or mono-block forging.

a. Fabrication by alternative method must be approved by the COR.

4. Compatible with existing components.

5. Provide Francis type runners with integral upper and lower rotating wear surfaces and cone with cone-to-runner coupling hardware as applicable.

a. Design wear ring clearances per approved hydraulic design.

b. Stepped seal design is not acceptable.

c. Grooved seal design is not acceptable.

6. Provide runners with holes through the crown hydraulic balance as necessary.

7. Shaft coupling elevation shall remain the same.

8. Design runners of sufficient strength to withstand forces due to runaway speed.

9. Design runners to support their own weight and the weight of the turbine shaft while resting on steel blocks on a ledge or on the shoulder of the discharge ring or draft tube throat ring for installation.

10. Shaft Fit:

a. Undersize runner to shaft bore by 0.100-inches.

b. Do not machine keyway.

G. Runner Manufacturing Requirements:

1. Fabricate runners per approved design.

a. Fabrication by alternative method must be approved by the COR.

2. Perform NDE inspections in accordance with ASME BPVC-V.

a. Provide method to be used for approval by Government.

3. The prototype runner profiles including leading and trailing edge shapes and geometry shall be homologous to the design, per IEC 60193.

a. Check and adjust each discharge passage outlet between adjacent buckets to obtain agreement within plus 3 percent to minus 1 percent of average opening dimension.

b. Check each outlet of the blades in at least three places equally distributed across the opening.

c. Check each inlet of the blades in at least two places equally distributed across the opening.

4. Runner to turbine shaft fit:

a. The Government will provide 3D laser scan of the existing runner.

48 13 10-7

b. Undersize runner coupling bore by 0.100-inch. USBR to machine to final fit to shaft.

5. No modifications allowed to discharge/throat ring or headcover.

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

H. Runner Castings Requirements:

1. Document major castings defects and extent of excavation:

a. Map size.

b. Submit repair details for approval prior to making repair.

2. Major repairs shall not be made to castings without approval of the Government.

a. Defects will be considered major when the depth of the cavity, properly prepared for welding exceeds 20 percent of the actual wall thickness or 1-inch depth, whichever is smaller.

3. When the Government permits repairs of major defects in castings by welding, utilize dye penetrant or ultrasonic inspection to:

a. Initially determine that the defect has been totally removed.

b. After welding and grinding are completed, determine the adequacy of the repair.

c. All inspections are at the expense of the Contractor.

4. Perform NDE inspections in accordance with ASME BPVC-V.

I. Runner Welding Requirements:

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

2. Final machining after welding is complete.

3. Design and Fabrication: Unless otherwise provided, welded parts conform to the following requirements:

a. Principal stress-carrying parts - The design and fabrication of welded parts subject to stress due to hydraulic pressure and of other principal stress-carrying parts in accordance with Part UW of ASME BPVC-VIII, with the following exceptions:

1) Localized stress-relieving 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.

48 13 10-8

J. Runner Finishes Requirements:

1. Surfaces of runner in contact with water passing across them: Machined or ground very smooth so that the surfaces are free from hollows, depressions, cracks, or projections that might cause incipient cavitation or pitting.

2. Finishes for runner water passages:

a. Average value: Between 63 and 125 micro-inch finish.

b. The lower one-third of the blades and the band: Between 32 and 63 micro-inch finish.

3. All other surfaces of the runner: At least 250 micro-inch finish.

4. Finishes finer than 32 micro-inch are not required.

5. Runner blade profiles: Conform to IEC 60193 standards for waviness.

6. The surface finish shall be in accordance with ASME B46.1.

K. Balancing the Runner Requirements:

1. Static or dynamically balance runner in accordance with ISO 1940/1 and with a balance quality of G6.3.

2. If required for balancing, weight shall be added or removed in such manner that there will be no projections or depressions from finished surfaces.

3. An eccentric cut shall be made for correction of balance.

a. The length of the cut must be a minimum 100 times the depth of the cut.

4. Indicate the method of weight adjustment on approval drawings.

L. Runner nose cone bolts:

1. Furnish new nose cone bolts and mechanical locking system, if required.

M. Inlet and Outlet Template Requirements:

1. Fabricate and furnish three (3) templates to fit the profile of the runner blade, spaced evenly across the discharge edge to aid in runner repair, per IEC 60193.

2. Fabricate and furnish two (2) templates to fit the profile of the runner blade, space evenly across the inlet edge to aid in runner repair, per IEC 60193.

3. Laser cut templates to match exactly the profile in designated locations considering the allowable tolerances.

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

5. Templates used to validate the final hydraulic profile.

6. Designed to be used in the field.

7. Deliver to Government with the final runner.

48 13 10-9

N. Turbine Nameplate Requirements:

1. Provide new nameplate to include the following information at a minimum:

a. Contractor Name and Logo

b. Max. Net Head

c. Min. Net Head

d. Speed

e. Runaway speed

f. Maximum discharge

g. Maximum Turbine Power, in horsepower

h. Unit Rotation, as viewed from above

i. Year

j. Unit Number

O. Mechanical Locking System:

1. Contractor to provide mechanical locking design for:

a. Runner Nose Cone to Runner Bolts, if required.

P. Shop Cleaning and Protective Coating:

1. Shop painting of the metalwork is not required; however, clean the surfaces of all metalwork of weld spatter before shipment.

2. After fabrication of stainless steel equipment, pre-clean, descale, clean, and passivate stainless steel surfaces per ASTM A967 or ASTM A380 to remove all grease, oil, paint, flux, weld spatter, slag, burrs, scale corrosion products, foreign metals, and other surface contaminants.

a. Perform a copper sulfate test or another approved method to detect if any free surface iron is present.

3. Cleaning and passivating methods selected to be consistent with the surface finish specified, the size of the part, and the specific alloy material.

4. Protect surfaces as necessary to preserve the finish until installed or delivered to the Government.

5. All other finished surfaces of ferrous metalwork, including screw threads, that will be exposed to the atmosphere during shipment to be cleaned and coated with a corrosion-preventive compound.

6. Post passivation: provide litmus test to ensure passivation process was successful.

a. Test 2 random locations on each runner blade, crown and band and provide results. If results are not accepted, repeat passivation process.

48 13 10-10

2.02 MATERIALS

A. Francis Turbine Runner:

1. Fabricate runners and runner cones from stainless steel in either cast, forged, or plate:

a. Cast:

1) ASTM A743 Grade CF3. Including supplemental requirements S2 through S7 and S12.

2) ASTM A743 Grade CA6NM. Including supplemental requirements S2 through S7 and S12 through S14.

b. Plate:

1) ASTM A240, UNS S30403.

2) ASTM A240, UNS S41500.

c. Forged:

1) ASTM A182, F304

2) ASTM A182, F6NM

B. Bolts and Studs: ASTM A193, B7

C. Nuts: ASTM A194, 2H

D. Profile Templates and Protractor Plate: Aluminum, minimum thickness of 0.125-inch.

2.03 NON-DESTRUCTIVE TESTING

A. See Specification Section 48 13 03 – General Testing Methods.

B. VT and PT Testing:

1. Perform 100 percent VT and 100 percent PT.

2. Components to be tested:

a. Crown, band, blades, runner, cone, and welds.

C. UT Volumetric Inspection:

1. Perform 100 percent UT per ASM BPVC-V for crown, band, and blades.

2. Components to be inspected:

a. Blade to Crown welds.

b. Blade to Band welds.

48 13 10-11

2.04 TRIAL ASSEMBLY

A. The following components will undergo a trial assembly prior to shipment to the

Government.

1. Runner and Runner Cone, if applicable.

2.05 PROGRESS INSPECTIONS

A. The Government or Government representative may perform progress inspections during the manufacturing process to verify compliance and quality. The Government may provide 48-hour notice of inspections. The Contractor shall accommodate the inspections.

2.06 WITNESS INSPECTION POINT

A. Provide 30-day notice before the start of the witness point milestone for Government technical engineers to verify:

1. Final inspection of cast components.

2. Initial homology of runner fabrication.

3. Final homology and dimensional check of the complete runner.

B. Final homology inspection of the runner shall be conducted at a location that is approved for travel by the Department of State (www.travel.state.gov), without additional protective services or safety requirements.

1. The location shall have all the necessary equipment and tools to perform an adequate inspection of the runner and associated equipment.

2. If the runner fabrication and inspection location does not meet these requirements, the Contractor shall relocate the runner to a machine shop within the United

States, for final inspection.

3. This relocation will be at the expense of the Contractor.

C. Provide templates and other means, such as 5-axis measuring machinery, to demonstrate homology conformance of the completed runner with model blade profiles in the shop in accordance with IEC 60193.

PART 3 EXECUTION

Not Used.

http://www.travel.state.gov/

48 13 10-12

Black Canyon Powerplant –

U1 and U2 Hydro Pump Turbine Runner Replacement

Boise Project, Idaho Specifications No. 140R1021R00xx

Information Available to Offerors

51 00 00 - 1

SECTION 51 02 80

OPERATIONAL DATA

PART 1 GENERAL

1.01 INFORMATION

A. Original manufactures operational curves:

B. Flowrate table from 1988 tests:

Information Available to Offerors

51 00 00 - 2

51 00 00 - 3

51 00 00 - 4

PART 2 PRODUCTS

Not Used

PART 3 EXECUTION

Not Used

U1 and U2 Hydro Pump - Turbine Runner Replacement

Boise Project, Idaho Specifications No. 140R1021R00xx

Drawings

52 00 00 - 1

SECTION 52 00 00

DRAWINGS

GENERAL

DISCREPANCIES, ERRORS, OR OMISSIONS

Promptly inform the CO of discrepancies discovered on the drawings. The CO will make a determination in writing. Any adjustment by the Contractor without such a determination shall be at its own risk and expense.

Anything mentioned in the written specifications and not shown on the drawings or shown on the drawings and not mentioned in the written specifications, shall be of like effect as if shown or mentioned in both. In case of differences between drawings and written specifications, the written specifications shall govern.

PROJECT CONDITIONS

Where there are differences as determined by the CO between details and dimensions shown on drawings and details and dimensions of existing features at jobsite, use details and dimensions of existing features at jobsite.

INFORMATION DRAWINGS

Drawings provide are for information only in the drawing list are included to show existing features about which knowledge is required to perform work under this contract. These drawings do not show work to be performed under this contract.

If there are differences as determined by the CO between details and dimensions shown on these drawings and those of existing features at jobsite, use details and dimensions of existing features at jobsite.

STANDARD DRAWINGS

Standard drawings may show details which are not a part of work under this contract. Disregard details shown on these drawings which are not applicable to work under this contract.

COPIES OF DRAWINGS

One set of full-size (22 inches by 34 inches) drawings, except standard drawings, will be furnished to the Contractor.

Upon request, additional half-size (11 inches by 17 inches) copies of standard drawings will be furnished to the Contractor.

Drawings

52 00 00 - 2

LIST OF DRAWINGS

Drawings listed in Table 52 00 00A – List of Drawings, are made a part of Section C -

Description/Specifications.

DRAWING NUMBERS IN NUMERICAL ORDER

Specification drawings are listed in numerical order in Table 52 00 00B - Drawings in Numerical

Order.

PRODUCTS

Not Used

EXECUTION

Not Used

Table 52 00 00A - List of Drawings

Sheet

No.

Drawing No. Title

Information Drawings:

1 3-D-339 General Arrangement Plan

2 3-D-341 Longitudinal Section

3 3M-100-782-27 30” Type Water Turbine Runner R.H.

4 N/A Sectional Elevation

5 3M-100-780-10 Top View

6 N/A Thrust and Upper Guide Rotating Components

Standard Drawings (provided after award):

7 40-D-7102 Government Drawing Format - Drawing Border, Sample

Title Block and Signature Lines

Drawings

52 00 00 - 3

Cabinet :' `•;. %"

Maq .Reversin Sw.

f ~~ J Gock•

~i8' Valve

I•,. I

--r' \ ---------------- ---,--- - 'r

EF

a

AirRecrivrr f's' `' 4 t 'Power ` •Venturi --- 1'

-Air-Pressure

Cabinet Meter :;, ; , f Governor

- r-- - •~---------------'~; ice•=--

~~-~---------=-------------=u- ~ •=-r!Corl~pressor \~2 0 M ------ ---~ --- ------

Q

---------J

Oil

. Q i I

No,/ Turbine 'i

-- r---------------------- - -

I

~~ ~._.~_ Pump Discharqe j

Oil

! I a•'•~f i:v

:: i I I u7pl

I~

Penstock

~j JI]i

Ii I

N

F..-O'lSh Button i'

Puilz-

~f _ ~' Penstock

II(

I I

OFFICE

I ' -o, Bench

Booth

STORE ROOM

Bench born -'

No. 2 Turbine Penstock

B

Static Battery Charginq Set Iran ~ad z6:I

~~ I----A- - I -j'--, -- i

- 'ID- F---- '~ I----1-- a -'—

- ---r------------- d --------L------ - J L---f---- ---------

.... ...................... - ......... ----•--- - - l?0V --------------------------------- -------------------- ----z0ra=--------•- -2510f ----------------------------------------- --2.3.0 --------------------- ---- - - ---------------------i ------- - - - -- - - -- ---------- I---- ------ ------- -- --------------- - ------------------------------------------------ - ----- -------- 10,?W------

A>

1 0 s 10 Is ll~.l I I I

Scale Of Feet

I

•ty I -- C

I I I I a

-- — --------------a0/o-- ------------------------- - ----------------- zr-3~----------------------------------- -______.___.. ....4L3!-- ..... ........................ 1C6L ----------------- ------------- - ---------------------------- 17!6£ -------------------------- .I DEPARTMENT OF THE INTERIOR _______________________________________________________________________________________-__________._.._._-__________________________-_-_-_._____•_-________________-_-r., BUREAU OF RECLAMATION

BT

BOISE PROJECT - IDAHO

BLACK CANYON POWERAND PUMPING PLANT

GENERAL ARRANGEMENT N

DRAWN, M.H.K.• C.A.M.

RccoMnrcenco • /(//////-(~ C4:`'~+~,I \

CNECMEnr ~•A•N.f~~• APPROVEOr ~N —_ -I

RECORD DRAWING DENVER

ShEE

O..DEC.3.1927 3-D-339 SHffT/ OF 4

DEPARTMENT OF THE INTERIOR

BUREAU OF RECLAMATION

Q, • BOISE PROLIECT -IDAHO

I

TIC SWITCHBOARD -

na,n ~°•:• nfin m

.I—

III

t_0____2=__0=__00

000000000000000

GENERATOR No.2 5000- Kv-a.

Kw. Exciter ` V. 380Amp.

e

~I e e ° • ffi • • ~'- - ~~

GENERATOR,

60"Penstock EI.2431 H ._Ql

E B4"Dischome

Iff SECTION C-C " e o 1 0 1 2345 10 15

Scale of Feet

BLACK CANYON POWER AND PUMPING PLAN

LONGITUDINAL SECCTIIONP

//JJ

DRAWN, M.N.K.,_ C'A'M. RECOMMENDED f ". /I-

CNECKED,CAN /I TI~'APPROVED

RECORD DRAWING DENVER,COLO.Nov. 25,1927 3-D-341 S HEET3 DF 4

° °• TURBINE No.2 6110 H.P.

z 80'Head ° 225 R.P. M h ~ .

b