Breaker Overhaul - PWS rev.2.pdf

PERFORMANCE WORK STATEMENT

XJ2 Breaker Overhaul John Day Dam, Sherman County, Oregon

1. GENERAL

• 1.1. Purpose. The XJ2 ABB Generator Circuit Breakers (GCB) Type HECI-5R located at U.S. Army Corps of Engineers (USACE), Portland District, at John Day Dam, Sherman County, Oregon is used to protect high-value electrical equipment, such as the main unit generator and the T1 transformer, from potentially catastrophic short-circuit faults. The breaker uses a hydromechanical spring operating mechanism HMB-4 which open and close the main contacts of the circuit breaker such as disconnect switches if needed. This GCB is beyond its design life, and the integrity of the hydromechanical spring operating mechanism is in doubt. It’s been showing signs of recharging issues and lack of maintaining spring charge. The Contractor shall furnish all management, supervision, labor, tools, materials, parts, equipment, transportation, and incidental items necessary to perform services in accordance with this PWS and all applicable federal, state, and local laws and codes.

• 1.2. Contract Type and Period of Performance. This requirement is anticipated as a firm-fixed-price (FFP) contract for a base period

• Base Year: 1 October 2026 through 30 September 2027

• 1.3. Transition / Baseline Inspection. Within seven (7) calendar days after contract start, the Contractor shall perform a complete and systematic baseline inspection of all covered breakers and provide a written report to the COR identifying:

• overall equipment condition

• code or safety observations

• immediate operational or safety concerns

• Any pre-existing Major Deficiencies the Contractor believes are outside the scope of this full-service contract.

• 1.4. Post-Award Conference / Pre-Work Meeting. After post-award submittals have been reviewed and accepted, the Government will schedule a Pre-Work Meeting no later than fifteen (15) calendar days after contract award. The COR will establish Government procedures for coordination, documentation, access, and communication. The Contractor shall present the baseline inspection report at the Pre-Work Meeting.

• 1.5. Lines of Authority. Only the KO may change contract scope, price, terms, or conditions. The COR may direct and coordinate technical performance within the scope of the contract.

2. DEFINITIONS

• Major Deficiency (Baseline): A pre-existing condition identified during the initial baseline inspection that the Contractor believes requires repair/alteration beyond routine maintenance and corrective repair typical of full-service GCB maintenance.

3. GOVERNMENT-FURNISHED SUPPORT

• 3.4. Government Furnished Equipment (GFE) – Limited Spares. The Government has a single unit of HMB 4.5 for an ABB Generator Circuit Breakers Type HECI-5R that will be provided as GFE at the COR’s discretion to support mission continuity.

4. CONTRACTOR REQUIREMENTS

• 4.1. General. The Contractor shall furnish all labor, materials, supplies, tools, equipment, and supervision necessary to provide full-service maintenance for all covered GCBs listed in Attachment 1, including cleaning, inspection, lubrication, adjustment, calibration, repair, replacement, testing, and documentation.

• 4.2. Covered Components. Services include components and accessories that were part of the original breaker installation, including but not limited to: operating mechanisms, controllers, control logic, gears, bearings, brakes, mechanical/hydraulic components, operating coils/springs, electrical contacts/coils/resistors, control and signal equipment, interlocks, and associated safety devices.

• 4.3. Control and Indication Systems. Contractor is responsible for replacement and labor for lamps, bulbs, sockets, and receptacles for breaker control cabinets and status indication systems and shall maintain emergency trip and control systems in operable condition.

• 4.4. Licensing. Contractors shall be licensed in the State of Oregon to perform high-voltage electrical equipment repair/maintenance. Contractor shall provide a copy of the current license to the COR no later than seven (7) calendar days prior to the Pre-Work Meeting.

• 4.5. Technician Qualifications. GCB maintenance, repair, inspection, testing, and emergency response services shall be performed by qualified high-voltage electricians or certified breaker technicians.

Apprentices or trainees may perform work only under the direct supervision of a qualified technician.

5. PERFORMANCE STANDARDS AND TECHNICAL REQUIREMENTS

• 5.1. Full-Service Monthly Requirements (FFP)

• 5.1.1. Scope and Pricing Intent. The intent of this contract is full-service GCB maintenance. The Contractor is responsible for all preventive and corrective maintenance and repairs necessary to keep covered breakers safe and operable, including trouble calls and emergency response, except for items identified as outside of scope.

• 5.1.2. Service Interruptions / Scheduling. Contractor shall schedule work to minimize disruption of generation operations. Mission-critical GCBs shall be restored to service as soon as practicable.

Contractor shall coordinate planned outages with the COR in advance and return equipment to service by the next business day unless otherwise approved by the COR.

• 5.1.3. Emergency Operating Procedures. Contractor shall submit written emergency operating/isolation procedures to the COR no later than seven (7) calendar days prior to the Pre- Work Meeting for responding to critical equipment malfunctions. The procedure is intended for use by qualified Contractor personnel only.

• 5.2. Preventive Maintenance Services

• 5.2.1. Monthly PM. Contractor shall perform preventive maintenance monthly for each breaker in accordance with manufacturer recommendations and applicable code requirements.

• 5.2.2. Written Maintenance Plan. Contractor shall produce a written PDF maintenance plan specifying recommended maintenance to be carried out on monthly, quarterly, yearly, five-year, and ten-year intervals.

• 5.3. Repair Services

• 5.3.1. Repairs Included - Contractor shall perform necessary repairs and replacements required to maintain safe, operable breakers, including labor, parts, and materials.

• 5.3.2. Contractor shall install, adapt, and calibrate Government-Furnished HMB-4.5 operating mechanism.

• 5.3.3. Refurbishment and Return of Removed Operating Mechanism – The Contractor shall safely remove the existing HMB-4 operating mechanism, transport it to the Contractor's facility, completely rebuild/overhaul it to meet or exceed original equipment manufacturer (OEM) specifications, and return the refurbished unit to John Day Dam as a spare.

• 5.3.4. On-site Classroom Training - The Contractor shall conduct on-site classroom training at John Day Dam for John Day electrical staff (up to 8 personnel). The training curriculum shall comprehensively cover the operation, routine maintenance, troubleshooting, alignment, and timing procedures for the breaker and the HMB-4.5 operating mechanism, as well as detailed, step-by-step procedures for the complete teardown, overhaul, and rebuilding of the operating mechanism. The Contractor shall provide all training materials, instructional handouts, and reference documentation to attendees upon completion.

• 5.3.5. Physical Enclosures. The following are excluded from Contractor responsibility unless specifically directed by the KO: concrete foundations, structural steel supports, bus work, and facility enclosures.

• 5.4. Trouble Calls and Emergency Calls

• 5.4.1. Regular Hours / Trouble Calls. For trouble calls during regular hours, Contractor shall arrive on site and initiate corrective action within 96 hours of notification.

• 5.4.2. Emergency Calls – Imminent Failure or Safety Hazard. For emergencies involving imminent equipment failure or personnel safety hazards, Contractor shall arrive on site within 96 hours of notification and perform corrective actions in accordance with approved procedures and applicable codes.

• 5.5. Testing and Inspection Services

• 5.5.1. Required Tests. Contractor shall perform safety inspections and tests on all GCBs as required by applicable IEEE, NETA, and NFPA standards. Tests include, as applicable:

• Breaker timing tests.

• Contact resistance tests.

• Insulation resistance (megger) tests.

• Functional trip and close circuit testing.

• 5.5.2. Check Sheets / Posting Requirements. Contractor shall develop and provide one check sheet for each breaker and post the check sheets in a COR-approved location.

• 5.5.3. SF6 Handling. Contractor shall develop and provide one check sheet for each breaker and post the check sheets in a COR-approved location.

• 5.5.4. The Contractor shall use standard SF6 gas handling, recovery, and reporting requirements such as but limited to gas-leak reporting, closed-loop recovery carts, and the use of certified gas technicians for work, and follow 40 CFR Part 82 and Part 98.

• 5.6. Technical Reporting Guidelines. Contractor shall provide prompt reporting following on-site service visits.

• 5.7. Safety. Contractor shall comply with mandatory USACE safety manual EM-385-1-1. Contractor shall provide an Accident Prevention Plan, and Activity Hazard Analysis. Contractor shall coordinate LOTO procedures with facility operations.

6. QUALITY ASSURANCE AND PERFORMANCE REQUIREMENTS SUMMARY (PRS)

• 6.1. Performance Requirements Summary (PRS)

Performance Objective Performance Standard

(AQL)

Surveillance Method Allowable Discrepancies

Monthly Preventive Maintenance (Sec 5.2)

100% of breakers receive required monthly PM; breakers maintained operable

100% review of records 0 missed PMs

Preventative Maintenance (Sec 5.2.1.)

≥ 95% of service visit reports submitted within 2 business days

100% review of submissions

1 per quarter

Trouble Calls During Regular Hours (Sec 5.4.1)

On-site arrival within 96 hours, 100% compliance

100% call log review 0

Emergency Response – Imminent Failure (Sec 5.4.2)

On-site arrival within 96 hours, 100% compliance

100% call log review 0

Technical Reporting (Sec 5.6)

Received within 24 hours of departure

100% call log review 1 per quarter

EXHIBIT A – SCHEDULE OF DELIVERABLES (REVISED)

Deliverable Due Date / Frequency

PWS Ref Format Submit To:

Baseline Inspection Report

Within 7 calendar days after contract start

1.3 PDF COR

HV Electrical License

No later than 7 calendar days prior to Pre-Work Meeting

4.4 PDF COR

Written Maintenance Plan

No later than 7 calendar days prior to Pre-Work Meeting

5.2.2 PDF COR

Emergency Operating Procedures

No later than 7 calendar days prior to Pre-Work Meeting

5.1.3 PDF COR

Posted Breaker Check Sheets

Prior to completion of first monthly PM

5.5.2 Posted COR–Approved

Location

AHA, LOTO

Procedure, APP

Within 7 calendar days after contract start

5.7 PDF COR

ATTACHMENT 1 – JOHN DAY DAM GENERATOR CIRCUIT BREAKER (COVERED)

The following Generator Circuit Breaker (GCB) is covered by this contract:

Location / Unit No.

Manufacturer Type Serial Number Year Manufactured

Powerhouse – Unit 2

ABB HECI-5R HA 2145-10 2005