Tg 5 15699 r1 11 Jul.pdf

MAINTAIN TURBINE-GENERATOR #5 SECTION 15699

EIELSON AFB, ALASKA TURBINE-GENERATOR OVERHAUL

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NOTE: Changes from previous version of this specification are written in BOLD type.

PART 1 GENERAL

1.1 SCOPE

A. This section covers the materials and methods required to overhaul a steam turbine-generator system.

1.2 SUBMITTALS

A. Temporary Floor shoring design -- calculations and drawings.

B. Qualifications of the Technical Representative who will oversee the disassembly, repair, start-up and testing.

C. Qualifications of the governor technician.

D. Qualifications of Testing and Inspection firm and the qualifications of the technician or technicians who will be performing the inspection.

E. Pre-Overhaul Vibration Report, clearances and float measurements.

F. Extraction Check Non-Return Valve: Manufacturer’s literature for the valve, hydraulic cylinder, limit switches, etc. Shop drawings and O&M manuals

G. Extraction Isolation Valve Actuator: Catalog data, and O&M data.

H. Mechanical, electrical and total runout at proximitor target areas.

I. Proposed coupling cover oil vapor control system: Shop drawings & catalog data.

J. Oil Filters: Catalog data for the main and control oil filter elements.

K. Hotwell Level Control: Manufacturer’s literature for the proposed liquid level controller, control valve, actuator and level switches.

L. Condenser cooling water meter:

1. Catalog data & shop drawings

2. O&M manuals

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M. Air Ejection System:

1. Design Calculations.

2. Drawings showing complete proposed pipe and equipment installation.

3. Manufacturer’s data for all system components: Inter-condenser and after-condenser, air ejectors, traps, pressure control valve, gauges, and manual valves. Include performance and capacity ratings for the entire system and all components. List materials of manufacture for all components.

4. As-built drawings of installed system

5. System operating and maintenance instructions.

N. Main Condenser Exhauster:

1. Provide catalog data, performance curves for the exhauster. Provide shop drawings of the

2. O&M manuals.

O. Field Ground Detection System Components: Catalog data, wiring diagrams, O&M data.

P. Turbine Control Panel:

1. The initial submittal shall include panel layout, shop drawings, wiring diagrams, and catalog data for all new components.

2. The final submittal shall include complete installation and operation manuals for all new panel components provided. In addition, provide complete shop drawings, and wiring diagrams. Submit paper copies of the

O&M manual as well as an equal number of CD-ROMs containing the complete O&M data in a PDF file.

Q. Modified EMD Panel:

1. The initial submittal shall include panel layout, shop drawings, wiring diagrams, and catalog data for all new components.

2. The final submittal shall include complete installation and operation manuals for all new panel components provided. In addition, provide shop drawings, and wiring diagrams for the devices installed under this

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15699r1 - 3 contract. Submit paper copies of the O&M manual as well as an equal number of CD-ROMs containing the complete O&M data in a PDF file.

R. Letters of Recommended Repairs.

S. Start-up Plan.

T. Post-overhaul report.

U. Completed Task Inspection List

V. Any proposed deviations from these specifications.

1.3 CONTRACTOR’S RESPONSIBILITY

A. From the start of pre-overhaul testing until the Contracting Officer approves the successful completion of the final acceptance test, the Contractor has full responsibility for the turbine-generator set, including its components, adjustments and operation. To ensure testing operations of the turbine-generator will not interfere with other plant operations or jeopardize safety, Government personnel will operate the machine at the direction of the

Contractor, provided that Government work schedules allow operators to be on hand and that actions requested by the Contractor, in the opinion of the operators, will not jeopardize plant operations or safety.

PART 2 - PRODUCTS

2.1 TURBINE-GENERATOR #5 NAMEPLATE DATA

A. #5 Turbine, CH&PP:

1. Manufacturer: Imo-Delaval

2. Serial #: 708483

3. P. O. #: 1650-0.001

4. Description: 10 Megawatt, 3600 rpm, with steam at 400 psig and 650 o F, 2 inches Hg absolute at outlet, extraction at 100 psig stage.

B. #5 Generator, CH&PP:

1. Manufacturer: Electric Machinery

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2. Serial #: 186365401

3. Description: 12,500 kVA, 3600 rpm, 3 phase, 7200 Volts.

C. Some Relevant Weights:

1. Generator Rotor -- 10,200 lbs

2. Turbine Casing Upper Half , including upper diaphragm halves, valve assemblies, servo motors and other attached appurtenances -- 35,200 lbs

3. Turbine Rotor Assembly – 19,475 lbs.

D. Operating and maintenance manuals are available for turbine-generator #5.

They will be available for review and use at the Central Heat & Power Plant.

Information not identified in these specifications might be found in the referenced manuals and is the Contractor's responsibility.

E. The turbine-generator and ancillary equipment have been modified since the equipment was originally installed. Where there is a conflict between what is shown in the original O&M manual and what is described in this specification, the contractor shall assume the specification is correct.

PART 3 - EXECUTION

3.1 TECHNICAL REPRESENTATIVE

A. The Contractor shall employ the services of the turbine manufacturer's technical representative or an independent technical representative. The technical representative shall be on-site to ensure proper overhaul, alignment, reassembly and test running of the equipment. The Contractor shall submit a written statement signed by the technical representative stating he (the technical representative) has inspected and approved the overhaul, balancing, alignment, reassembly and testing, and has witnessed and approved the post overhaul acceptance test. The technical representative shall have at least five years experience supervising the overhaul of extraction steam turbine-generator units, similar to Eielson’s turbine #5. Based on the qualifications submitted, the Contracting Officer will determine whether the technical representative proposed by the Contractor has sufficient experience.

3.2 GOVERNOR TECHNICIAN

A. The Contractor shall employ a governor technician either approved by

Woodward or having a minimum of three years experience adjusting and

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15699r1 - 5 calibrating Woodward electronic governors with extraction control. Based on the qualifications submitted, the Contracting Officer will determine whether the governor technician proposed by the Contractor has sufficient experience.

3.3 TEMPORARY FLOOR SHORING

A. Employ the services of a registered professional engineer to examine the loading to which the turbine room floor will be subjected during the overhaul.

The engineer shall design shoring or bracing as required to prevent failure of the turbine room floor when heavy turbine components are placed on it. The shoring shall not interfere with the continuous operation of the plant. The

Contractor shall submit the engineer’s calculations and recommendations, bearing his stamp, to the Contracting Officer for approval. The turbine shall not be disassembled until the shoring design has been approved by the

Contracting Officer and the shoring has been installed by the Contractor. The

Contractor shall remove all shoring when the overhaul is complete

3.4 TOLERANCES

A. Monitor product fabrication and installation tolerance control to produce acceptable work. Do not permit tolerances to accumulate.

B. Comply with manufacturer’s tolerances.

C. Adjust products to appropriate dimensions; position before securing products in place.

3.5 TEAR-DOWN, INSPECTION AND REPAIR OF TURBINE-GENERATOR

ASSEMBLY

A. All parts removed from the turbine-generator assembly shall be neatly arranged, stacked, identified and covered for purposes of location and protection. Laydown area to be determined with plant management.

B. Provide at no additional cost to the Government all parts that normally must be replaced for proper reassembly of the equipment described in this

Specification. i.e.: gaskets; sealants, single-use bushings, spacers or shims;

small nuts and bolts; etc.

C. After completing each of the Tasks identified in the attached “Task

Inspection List”, but before concealing it, the contractor shall request an authorized Government representatives inspect the work. If the Task is

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15699r1 - 6 determined to be completed, the authorized representative will sign and date the “Task Inspection List” and the contractor may continue with the work of the contract. Work may continue while waiting for inspection and approval as long as the work to be inspected will not be concealed.

Inspection of the work, witnessing of testing or signing the Task Inspection

List by the Government’s authorized representative in no way relieves the

Contractor of the obligation to perform the work in accordance with the requirements of the Contract Documents. The Government’s inspections are not intended, nor implied, to replace or supplement the Contractor’s Quality control Personnel and Procedures.

D. Contractor shall hire an independent test agency to record vibration. Record vibration readings while the unit is in operation prior to disassembly as well as after overhaul. Record vibration levels at full speed and no load, 1 MW, 2.5

MW, 5 MW, 7.5 MW and 10 MW. Record vibration at bearings #1 through

#4. Submit pre-overhaul vibration report within 14 days after vibration measurements have been taken. Disassembly of the machine may begin prior to submittal of the vibration report. Vibration monitoring equipment shall be provided by the contractor and may be connected to the existing vibration monitor to pick up outputs from the existing proximitors. The existing monitor is not guaranteed to be accurate.

E. Disassemble and tear down the turbine. All disassembly, cleaning and preparations for reassembly, including the use of special compounds and lubricants, shall be in accordance with industry accepted engineering practice and manufacturer’s recommendations. The contractor is responsible for removal of any insulation or lagging which must be removed to allow disassembly of the turbine.

F. High Pressure Casing: Clean joints of oxidized compounds and remove all burrs from joint surface. Visually examine diaphragm steam joints for steam cutting, clean, and recommended repairs to joint surfaces. Clean and visually examine threads of casing bolts and nuts. Check eroded or corroded areas, and recommend repairs or replacement. Make up joints using high temperature joint compound and thread lubricant. Stress bolts to proper values. Clean and check shaft packing and packing boxes. Check casing for any cracks.

Determine depth of cracks and recommend repairs.

G. Exhaust Hoods: Clean joints of oxidized compounds. Visually examine 4-way corner areas for leaks. Visually examine diaphragm steam joints for steam cutting and corrosion. Visually examine struts for erosion and cracked welds.

Check joints of steam seal piping. Check and clean casing drains.

Recommend repairs for all faulty exhaust hood components.

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H. Extraction Check Non-return Valve: Replace the extraction check non-return valve and operating mechanism. The existing valve is an, 18-inch, Class 300

Gimpel, Dwg number NP2222, with hard packing, double leakoffs, flanged ends, operating cylinder and counterweight.

I. Extraction Isolation Valve: Replace the valve actuator and gear drive.

Existing actuator is a Limitorque T-150 manual valve control with a model

SMC-041 electric control unit.

J. Steam Line Strainer: Clean and inspect main steam strainer and check for contamination or damage. Disassemble strainer and examine for any kinds of foreign material, holes, and remove any embedded materials. Check screen for embrittlement. NDE strainer using dye penetrant, or other method capable of revealing similar hairline cracks. Recommend repairs if faulty.

K. Atmospheric Relief Valve: Disassemble and clean valve. Examine for any erosion, leaks, and for freedom of operation. Check for foreign matter in relief piping from the atmospheric relief valve to the turbine. Lap valve disk and seat. Check seat to disc contact. Recommend repairs if faulty.

L. Primary and Secondary Control Valves: Clean and inspect all steam admission and extraction valves, seats, stems and linkages. Examine for evidence of leaking, stickiness, abnormal bushing clearance, cracks, etc.

Completely disassemble and clean all component parts. Replace all valve stem glands. Check stems for straightness, then record any runout. Visually inspect seats, discs, and seat seal welds. Check valve-to-seat contact. Lap valves and seats to ensure proper seating. Check and record sequence of valve openings and make all cold settings. Recommend control valve repairs if faulty. Valve stem glands to be replaced shall include, but not be limited to, the following part numbers:

IMO-Delaval primary and secondary steam valve glands

Quantity OEM’s Part Number OEM’s Symbol Number

2 43 MI804 AV

2 34 MI804 AL

M. Primary and Secondary Valve linkages. Clean and inspect all steam admission and extraction valve linkages. Completely disassemble and clean all component parts. Clean and inspect lifting bar, spindles, links, levers, forks, and spacers. Replace the lever end bearings (IMO-Delaval Part

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Number 23 on Drawing TCA4415 BP and Part number 17 on Drawing

TCB4415 F. Two bearings per lever.). Recommend repairs if needed.

N. Primary and Secondary Servomotors and Actuators. Return the existing

Woodward actuators to a manufacturer authorized service center for rebuilding. The existing actuators shall be disassembled and cleaned.

Replace seals, o-rings, packings, gaskets ands any worn parts. Actuators are

Woodward Electro-Hydraulic. Disassemble, clean and inspect the servomotors. Check pistons and other moving parts for freedom of operation and correct clearances. Replace gaskets, o-rings and seals. O-rings and seals shall be Viton. Recommend repairs if any are needed.

O. Clean and inspect all labyrinth seals on the turbine rotor shaft. Recommend any replacements if seals are not in good condition.

P. Clean and inspect the turbine-generator shaft coupling and recommend repair or replacement if needed. Coupling is a Deck model 6HSMA-LEF X33”

BSE GR. CPLG. ASSY (5/16 TOTAL FLOAT) (103674-87), drawing number: DKB33547, bill of materials: DKA 37024.

Q. Replace the turbine rotor ground brush (Imo-Delaval part number 96, symbol number 419196).

R. Record thrust bearing and total float clearance readings prior to and after overhaul. Rebabbitt and reinstall turbine and generator rotor bearings. Replace turbine thrust bearing shoes. Re-babbitt existing thrust shoes and return to plant stores. Visually examine for evidence of excessive loading. Visually inspect bearing oil seals, and recommend repairs if faulty. Check and record bearing clearance at reassembly. Bearing Data:

Thrust bearing – Kingsbury Drawing 150B-BD; IMO-Delaval DWG

RJ4200A, Item 34

Turbine Bearings – Imo Delaval Tilt Pad Assemblies (Part number 32, symbols GP395DA & GP395DA0001), 13” x 8” x 6-½”

Generator bearings – Spherical seat journal bearings, 9-1/2” x 6.0” x 8.0”

S. Remove and clean turbine rotor assembly. The power plant has a rotor stand that will be available for the contractor’s use. Visually inspect diaphragms, nozzle blocks, and rotor wheels. Record journal sizes with a micrometer and check for scoring. Check rabbit fit. Measure and record nozzle partition erosion. Check and repair crush pins. Blast clean turbine wheels, diaphragms and nozzle blocks. Contractor shall furnish aluminum oxide and blasting pots for use with 100 PSI air for cleaning. An area will be provided outside the

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15699r1 - 9 power plant for the contractor's blasting shed. The contractor is responsible for removal and cleanup of all blasting material. Blast cleaning shall be performed at Eielson AFB.

T. Primary and secondary nozzle rings and guide (reversing) ring: Remove, blast clean and inspect the first stage nozzles, Curtis wheel reversing ring and the secondary nozzle ring. Examine the discharge edges of the partitions, spill strips, holders, belting and keys. Replace caulking strips. Recommend repairs if faulty.

U. {This paragraph has been deleted.} Finish grind, polish, and demagnetize the four vibration probe target areas adjacent to each bearing journal on the turbine and generator shafts as necessary to reduce total combined mechanical and electrical run-out to no more than 0.46 mils. The final average surface roughness shall not exceed 32 micro-inches (IAW API

Standard 611, 5 th

Ed, Paragraphs 6.7.2.3 & 6.9.4.6.). Submit final values of surface finish roughness, mechanical runout and electrical runout.

V. Oil Deflectors: Remove accumulation of carbonized oil or other foreign materials from teeth of deflectors. Check and record deflector clearance.

Visually examine for rubs. Sharpen deflector teeth and clean lower half drain holes. Recommend repairs for all faulty oil deflector components.

W. Mechanical Emergency Overspeed Governor: Disassemble and examine for deposits and fretting corrosion. Check operation and trip setting before unit is returned to service. Recommend repairs if faulty.

X. Trip and Throttle Valve: Visually examine for evidence of sticking, or cracks.

Visually examine steam side of valve body. Replace bushings (Gimpel trip & throttle valve (Job Order: 86-14769, Customer #: 708487-151): Part numbers 20, 21 and 94). Re-establish design stem-to-bushing clearance.

Check stem for straightness, record any runout. Visually inspect seat to disc contact and check all seat seal welds for cracks. Check for full travel and free movement. Clean all surfaces and bolting of oxidized joint compound.

Recommend throttle valve repairs if faulty.

The valve currently leaks a small amount of oil, as does the trip console rear cover. The Contractor shall locate and correct the cause of these leaks.

Y. Examine for wear and freedom of operation all other tripping mechanisms and linkages. Inspection shall include all overspeed, low oil pressure and high vibration safety trips. Recommend repairs if faulty.

Z. Condensate Pumps: Disassemble, clean and inspect both main condensate pumps. Replace mechanical seals, packings, bearings and shaft couplings.

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Provide two spare sets of seals. Inspect casings, impellers, shafts, etc.

Recommend additional repairs if needed. Condensate pumps are Flowserve

Model 10 EJY / 10 ELL-2, SN: 0806MP004553-1 and 0806MP004553-2, 225 gpm each at 100 ft head & 1775 rpm.

AA. Oil Pumps: Rebuild the main, auxiliary and emergency oil pumps.

Disassemble oil pump for visual inspection of pump gears. Check gear end clearance. Check bearing clearance and record. Check oil pump housing for any scoring. Replace all bearings, seals and packings. Recommend additional repairs if necessary. The existing main and auxiliary oil pumps are

IMO-Delaval part number G3DBC-250. The emergency oil pump is IMO-

Delaval G3DBC-187

BB. Motor Bearings: Replace the main, auxiliary and emergency oil pump motor bearings and seals. Replace the condensate pump and steam seal condenser fan motor bearings and seals.

Electric motor data

Main Oil Pump: General Electric, 25 Hp, 480 V, Model:

5KS284QPL2JB3A, serial number: RKP5161M501A

Auxiliary Oil Pump: General Electric, 25 Hp, 480 V, Model:

5KS284QPL2JB3A, serial number: RKP5161M501B

Emergency Oil Pump: General Electric, 7.5 Hp, 125 V DC, Model:

5CD152XD806B800, serial number: SB-8-1168-SB

Condensate Pump Motors: U.S. Motors, 10 Hp, 460 V, 3 phase, 1760 rpm, Model G7687532-100, ID numbers: N07-07687532-100M D04 01 and N07-

07687532-100M D04 02.

Steam Seal Condenser Fan Motor: Baldor, 3 Hp, 460V, 3 phase, 3470 rpm, Cat #: M3660T, Spec: 06C10W813H1, SN: F0803292164.

CC. Main Oil System: Clean and inspect the two oil coolers. Pull and check oil coolers for plugged or dirty tubes. Flush and clean oil system. Refill and test for leaks. Recommend repairs if faulty.

DD. Install an oil vapor control system at the turbine to generator coupling housing. Provide an oil vapor extractor. Pipe the condensed oil from the extractor to the main oil tank. Route piping to avoid obstructing the normal movement of plant personnel carrying out their typical duties. Route piping parallel to building lines and sloped to the oil tank.

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EE. Main Oil System: Inspect and clean oil coolers & auto control valve. Flush and clean the oil system. Drain and clean the oil tank. Clean and inspect the two oil coolers, including heads, baffles, tube sheets and interior of shells. Pull the tubes and check oil coolers for plugged or dirty tubes. Disassemble, clean and inspect oil strainer. Flush and clean oil system. Refill and test for leaks.

Install a temporary filter or screen in the oil return piping. Flush system until no visible sediment is captured by the temporary strainer. Recommend repairs if faulty.

Replace the main oil filter elements. Main oil filters are duplex Hilco Hyflow model F2-6E. Filter elements are 5 micron, pleated polyester.

Rebuild the oil temperature control valve assembly. At a minimum, disassemble and clean the valves; replace plugs, seat rings, all gaskets, seals, packings and o-rings. Disassemble clean and inspect the valve actuators. At a minimum, replace diaphragms and o-rings. Inspect and test temperature control valve to ensure proper response to temperature changes. Oil

Temperature control valve, actuator and controller are by Fisher. Controller is a Wizard, Valve is a 2” type ED, order number 708482-158. Actuator is a type

657, size 40. Serial Number for valve / actuator assembly is 10277709.

FF. Hydraulic Box: Replace the seals and packing in all 2-valve manifolds and ball valves in the Hydraulic Box. Replace the control oil filter elements.

Control oil filters are from the Commercial Filters Division of the

Carborundum Company, model BDX1-10-1/2SD. Replace the honeycomb filter tubes, part number 100440.

GG. Oil Purifier: The oil purifier is a Kaydon, model KL10. Replace the filter cartridges. The piping on the skid has several leaks. Repair the leaks. Assume

5 leaking flange gaskets. In addition, replace a leaking union in the 1-inch oil return line, east-southeast of the main oil tank.

HH. Main Condenser: Clean, and inspect the tubes in the main condenser. Replace anode if less than 50% of original mass remains. Test for leaks recommend any repairs needed to condenser or tubes. Condenser is a Graham, serial number 61120-1.

Condenser Liquid Level Control. Replace the liquid level controller (Fisher

Level-Trol Type 249, SN: 10254324), and the three level switchers

(Magnetrol Model 911-A1A0-A10, 581-1A22-008, 120V, 10A, DPDT).

Rebuild the 2-inch Fisher recirculation valve and actuator, and the 3-inch

Fisher backpressure valve. At a minimum, disassemble and clean the valves;

replace plugs, seat rings, all gaskets, seals, packings and o-rings. Disassemble

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15699r1 - 12 clean and inspect the valve actuators. At a minimum, replace diaphragms and o-rings. Install and adjust new components to ensure proper operation.

II. Condenser Water Meter. Provide and install an electro-magnetic flow meter in the 24-inch condenser water supply line. Install the meter in the pipe trench in the basement floor. Install the meter display on a column near the east end of the condenser. Meter shall display both flow rate and total flow.

Meter shall have an “empty pipe detection” feature. Meter shall be Badger

Meter model M-2000 or similar.

JJ. Air Ejector System. Replace the entire air ejection system. Provide and install a new system mounted on the basement floor, against the wall, east of the turbine. Modify cooling water, steam, condensate and vacuum piping as necessary to connect to the new condensers and ejectors. Provide a means to return condensate from the new air ejection system to the hot well.

The new system shall be approximately 5 feet lower, 14 feet east and 6 feet north of its existing location. Install the condensers of the new system parallel to the east basement wall. Modify and extend cooling water (4-inch supply and return), steam (1-1/2”, 100 psig), condensate (two lines, 1-1/2” each), drain (2 lines, 1-1/2-inch each), ejector safety relief valve discharge (two relief valves, 1-inch discharge each), and vacuum piping (4-inch from ejectors connects to

4-inch at main condenser and 3-inch from hogger jet), as necessary. Install all piping as high as practical where new pipes cross walkways and other personnel traffic areas. Provide a duplex electric condensate pump, if necessary, to return condensate from the new air ejection system to the hot well. Provide isolation valves for steam, and cooling water supply and return at the new system.

Provide new steam piping from, and including, the strainer in the main (1-1/2”) steam supply. Provide new vacuum piping from the first isolation valves upstream. Provide new cooling water supply piping from the first isolation valve upstream. Provide new cooling water return piping from the first isolation valve downstream. Provide new condensate piping to, and including, the steam traps.

If a steam pressure reducing valve is installed, provide isolation valves on both sides, and a bypass line with manual globe valve around the pressure reducing valve. Provide steam pressure gauges on both sides of the pressure reducing valve. Provide vacuum gauges between the inter-condenser and after-condenser, and downstream of the after-condenser. Provide a manual vacuum breaker valve. The new system shall have two stages and two elements. Each element shall be sized for the full vacuum load required by the turbine and main condenser. The existing system utilizes a combined inter and after

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15699r1 - 13 condenser. The new system shall have separate, not combined, condensers.

Where new pipes cross walkways and other personnel traffic areas, install all piping as high as practical.

The existing system components include the following: Condenser is Graham

10x8 Inter/After Condenser, SN: 61120-4, national board number: 15329.

Ejector nozzles are Graham Ejector serial numbers 61120-2, 61120-3, 61120-5, 61120-6.

Existing pipe connection sizes -- Cooling water (4-inch supply and return), steam (1-1/2”, 100 psig), condensate (two lines, 1-1/2” each), drain (2 lines, 1-

1/2-inch each), ejector safety relief valve discharge (two relief valves, 1-inch discharge each), and vacuum piping (4-inch from ejectors connects to 4-inch at main condenser and 3-inch from hogger jet)

Replace hogger jet nozzle. Relocate the hogger jet. Either mount it in approximately the same location, but lower, or mount it adjacent to the new air ejection system. In either location, it should be easy to access from the floor, out of walkways, and not block access to other equipment. The hogger jet does not need to be relocated or replaced. The hogger jet ejector is a

Graham ejector, SN: 61120-7.

Demolish the existing air ejection system, and the access catwalk and ladder.

KK. Replace the main condenser exhaust fan. The existing exhauster is an

Ametek Rotron blower, catalog number: 550641, Spec number:

376884Y47861. Fabricate and install an angle iron stand for the exhaust fan.

Stand shall be as low as possible, but tall enough so that the piping at the fan doesn’t touch the basement floor. Locate the fan just north of the east support for the main condenser. Verify location with plant superintendent before installation. Locate fan to avoid blocking access to other equipment and valves, avoid blocking walkways and provide good access for maintenance. Provide a new isolation valve in the fan inlet piping in a location easily accessible by plant operators and no more than 60 inches above the basement floor. Provide a new drain valve in the inlet piping below the fan inlet. Valves shall be bronze gate valves, Class 125, rising stem, and union bonnet.

LL. Steam Seal Control System. Rebuild the steam seal supply and dump valves and actuators. At a minimum, disassemble and clean the valves; replace plugs, seat rings, all gaskets, seals, packings and o-rings. Disassemble clean and inspect the valve actuators.

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Existing supply valve assembly is a 1-inch Fisher Model 667-EZ-3582GR (, serial number: 18583547, 3/8” port size). The dump valve assembly is a 2-inch Fisher Model 657-ED-3582GR (serial number: 18583648, 2-5/16” port size).

Rebuild the steam supply and dump valve positioners and the controller.

Positioners are Fisher model 3582. Controller is Fisher model 4195B steam seal pressure controller.

Gland Seal Condenser: Clean, inspect and hydro-test the gland seal condenser.

Recommend repairs if required. Condenser is a Basco model 08066, serial number 870096-01.

Disassemble, clean and inspect the gland seal exhaust fan. Replace fan bearings. Fan is Buffalo Forge, Model 3-RE, 21.5” wheel, serial number:

87301902.

MM. Automatic drain valves: Rebuild all five auto drain valves and actuators – three on the turbine room floor and two in the basement near the ceiling.

Replace the associated thermodynamic steam traps and the strainers upstream of the traps. At a minimum, disassemble and clean the valves; replace plugs, seat rings, all gaskets, seals, packings and o-rings. Disassemble clean and inspect the valve actuators. At a minimum, replace diaphragms and o-rings.

Valve bodies are Fisher model EZ. Actuators are Fisher model 667. There are three 1-inch valves and two ¾-inch valves. All drain valves are Class

600. Recommend additional repairs if necessary.

NN. Disassemble cooling water lines. Flush and clean the lines with high-pressure water jet to remove accumulated material from inside pipes. Clean piping from the three booster pumps to the steam seal condenser, oil coolers and stator coolers. Identify any sections of pipe that cannot be adequately cleaned.

Approximate pipe lengths: 6” diameter – 90 feet

4” dia. – 75 feet

3” dia. – 180 feet

2-1/2” dia. – 120 feet

OO. Stator: Visually examine stator unit, observing any unusual irregularities, such as presence of foreign material, loose slot spacers and wedges. Visually examine windings for signs of over-heating, distortion between phase belts, presence of corona, condition of lacing and blocking between turns, mechanical damage to insulation or any other irregularities. Remove field for examination of core wedges, ventilating ducts, girth cracks, armor openings, FTQW 12-1015

15699r1 - 15 or any other irregularities. Clean stator with dry air and proper solvents.

Visually inspect surface of stator core for signs of damage or localized heating of laminations. Check rib nuts, clamps, and cores and end flanges.

Recommend stator repairs if faulty.

1. After heating and drying the stator sufficiently to allow for accurate electrical testing, perform and record the following electrical tests in accordance with the generator manufacturer’s recommended procedures:

a. 10-minute megger and polarization index

b. Winding copper resistance

c. RTD resistance check and megger test

d. DC leakage test and DC high-potential test.

2. Notify the contracting officer and plant superintendent a minimum of one working day prior to electrical testing.

PP. Field: Remove field. Fabricate, and use necessary skid pan, skid shoe, mat and cribbing required to properly remove and place field on concrete floor of the CH&PP. All fabricated components used will become property of the

Government for reuse. Visually examine rotor for signs of mechanical damage. Visually examine fit areas and locking devices for any signs of looseness. Visually inspect retaining rings for any mechanical damage.

Clean field with dry air and proper solvents. Check retaining rings for signs of arcing. Inspect ventilating holes throughout field body. Visually examine, retaining rings and blocking. Visually examine aluminum saddles or radiating plates for looseness, and distortion. Visually inspect slot wedges, which may have moved. Visually inspect the ends of the field body for signs of localized heating. Inspect cooling fan rings for crack indications or signs of fatigue. Inspect collector rings. Recommend repairs to all faulty field components.

1. After heating and drying the field sufficiently to allow for accurate electrical testing, perform and record the following electrical tests in accordance with the generator manufacturer’s recommended procedures:

a. 10-minute megger and polarization index

b. Winding copper resistance

c. AC impedance test.

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2. Notify the contracting officer and plant superintendent a minimum of one working day prior to electrical testing.

QQ. Exciter: Disassemble, clean and inspect the exciter. Replace all diodes and fuses. Perform 10-minute megger test and develop polarization index. Check phase to phase resistance and insulation resistance in armature and field coils.

Recommend additional repairs if any are needed.

RR. Field Ground Detection System: Replace both the rotating transmitter and the stationary receiver.

SS. Electric Leads: Inspect and test insulation on electrical leads from the generator to the terminal blocks under the generator and electrical leads from the exciter to the generator. Recommend repair or replacement if needed.

TT. Generator Air Coolers: Replace the upper cooler with a new Government furnished cooler. Clean, flush, inspect and hydro-test lower cooler. Clean and straighten fins. Recommend additional repairs if needed.

UU. Clean equipment and floor inside the high voltage cage. Clean all exposed surfaces of the current limiting reactor and the neutral ground resistor.

Remove accumulated dust, dirt and grime.

VV. Vibration Monitoring System: Inspect the vibration monitoring system.

Existing vibration monitoring system is a Bently Nevada 3500. Check and adjust, if necessary, the alarm and shutoff system. Verify proper functioning of proximitors. Inspect condition of cables and insulation between monitor rack and probes. Test all temperature probes and speed pick-up for proper functioning. Recommend repairs if any are determined to be necessary.

WW. Perform non-destructive testing (NDT) on turbine wheels, diaphragms, nozzle blocks, reversing ring, rotor shaft, valves, valve seats and main steam line strainer to reveal any cracks or defects. At a minimum, the individual conducting the NDT must hold a level two Non-Destructive Testing certificate with the American Society for Nondestructive Testing. Non-destructive testing must be performed at Eielson AFB.

3.6 RECOMMENDED REPAIRS

A. Within five (5) days after inspection of any component for which the contractor recommends repairs or replacement not already required by the specifications, submit a Letter of Recommended Repair (LRR). Contractor shall not let the LRRs accumulate. Each LRR shall include a detailed listing of all components, to include part number, model, descriptive nomenclature, FTQW 12-1015

15699r1 - 17 and manufacturer as well as suggested sources of procurement and lead time for arrival on site. Additionally, the contractor will supply the specific reference which identifies the component as being out of compliance with manufacturer requirements and/or recommendations. Each LRR shall also include a description of the component’s condition, recommended repair or replacement, cost proposal and estimated time to complete the recommended work after Notice-to-Proceed has been received. Each cost proposal shall show itemized material and subcontractor costs, as well as labor hours and rates. If defects in components are discovered, which, in the contractor’s opinion, are optional to correct, the contractor shall submit a letter describing the defect. The Contracting Officer will review the information provided by the contractor and decide whether or not to make the optional repair.

B. The Contracting Officer will review each LRR submitted. If the recommended additional repair is approved, a fair and reasonable price will be negotiated and the Contractor will be issued a Notice-to-Proceed with the repair.

C. For approved repairs, furnish all needed parts and repair services, welding, machining and reshaping of turbine components to restore to within manufacturer's specified tolerances.

D. The contracting Officer may add Inspection Items to the “Task Inspection

List” based on the type of work included in the accepted LRRs.

3.7 REASSEMBLY

A. Balance turbine rotor and generator field assemblies. Notify contracting officer and plant superintendent a minimum of one working day prior to final balancing. The turbine rotor and generator field shall be dynamically balanced so that the maximum residual unbalance (Umax) shall not exceed 4 x

W/N (where W= the journal static weight load in pounds, N = the maximum continuous speed in rpm, and Umax is in oz-in). NOTE: Maximum unbalance may be extrapolated to 3,600 rpm if the portable balancing equipment cannot safely spin the rotors at that speed.

B. Reassemble turbine. Perform a complete centerline alignment. Measure and record clearances of rotor and turbine components, thrust bearing and total float. Record alignment information for all diaphragms. After reinstalling diaphragms and rotor, but before reinstalling upper casing half, notify

Contracting Officer and demonstrate to his satisfaction that proper alignment

(diaphragms, seals and shaft) and clearances have been achieved. Provide at

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15699r1 - 18 least one week-day notice prior to the demonstration. Demonstration may be divided into multiple events at the Contractor’s discretion.

C. Reassemble generator. Perform complete centerline alignment. Measure and record clearances and alignment. Check and measure air gaps. After reinstalling the generator, but before reinstalling the generator cover, notify

Contracting Officer and demonstrate to his satisfaction that proper alignment and clearances have been achieved. Provide at least one week-day notice prior to the demonstration. Demonstration may be divided into multiple events at the Contractor’s discretion.

D. The turbine casing is insulated with reusable insulating blankets. Reinstall the blankets and securely fasten them to the machine. Any blankets damaged or soiled by the contractor shall be replaced at contractor’s expense.

Reinstall existing lagging.

E. Insulate the trip and throttle drain piping with 2-inch thick, preformed calcium silicate insulation with manufacturer’s standard jacket. The trip & throttle drain is 1-inch diameter. Insulate the trip & throttle drain line from the main steam supply line to the isolation valve just upstream of the auto drain valve and the isolation valve upstream of the steam trap. There is approximately 8 feet of pipe, three elbows and one tee to insulate.

F. Prepare a proposed start-up and adjustment plan outlining all steps and procedures, in sequence, the contractor intends to perform to ensure the reassembled machine is correctly adjusted and operating properly. Do not proceed with start-up or adjustment until the start-up plan has been approved by the Contracting officer.

3.8 TURBINE-GENERATOR CONTROL PANEL

A. Replace the meters, gauges and switches in the existing turbine control panel.

Refer to appendix 2 for a photograph of the existing panel. Provide a new painted steel panel face with all new cut-outs to accommodate the instruments and controls. Existing control panel is 96” high x 120” wide and

24” deep. There is a 10-inch high sheet metal bracket on top of the panel supporting a fluorescent light fixture, which illuminates the panel face.

Provide the panel face with a new logical, easy to use and read layout, similar to the layout shown in Appendix 4.

B. Provide all new controls, and instrumentation, except as described below.

Reuse the following equipment: The Bently-Nevada monitor, module rack and keyboard; the Yokogawa monitor; and the Woodward 505E governor.

The Yokogawa monitor displays the following inputs: Throttle steam flow

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(total steam flow through the T&T valve, kpph), Inlet Steam temperature o F), Vacuum (inches Hg), Steam totalizer (kilo-pounds), Extraction steam flow (kpph), extraction steam temperature ( o F), and extraction steam totalizer

(kilo-pounds). Reinstall the existing mercury-filled vacuum gauge. Take appropriate precautions to avoid spilling mercury or allowing the mercury to come into contact with exposed skin.

C. Relocate the following diesel generator controls and gauges from the existing

Turbine 5 panel to the “EMD control panel” on the east side of the turbine room: 1) Basler Manual Voltage Adjustment controller, 2) Diesel Generator

H-O-A switch (H-O-A sector switch, labels: “Diesel Generator Hand-Off-

Auto”, “Leave in Auto for GE” and “Off or GE Start/Stop”), 3) Diesel

Generator Voltage Adjust (labels: “Diesel Gen Voltage Adjust”, “Raise” and

“Lower”), 4) Diesel Generator Soakback Pump (On / Off selector switch, labels: “Diesel Generator Soakback Pump” and “Run 20 Min Before and

After Starting Diesel Gen”), 5) Emergency Stop (red pushbutton, label:

“Diesel Gen Emergency Stop”), and 6) Diesel Generator Exciter Voltage gauge (Gauge 0-150 DC Volts, label: “Diesel Generator Exciter Volts”).

Except for the Basler controller, p Provide all new components – meter, switches, etc.

To minimize the time period when the diesel generator is not available to provide power, install all the new controls and wiring prior to disconnecting the existing controls.

D. Provide the new panel with a keyboard tray that slides in and out of the control panel.

E. Provide round combination LED bar graph / digital gauges for the new panel.

Gauge face shall be round and a minimum of 6” in diameter. Gauges shall be powered by 120V AC. Gauges shall have red digital LED displays with four or five digits, each at least 0.6 inches high. In addition, each gauge shall have a circular bar graph made up of at least 50 LED segments. Bar scale LEDs shall be red, yellow or green as indicated below. Gauges shall have serial output via RS 232 or RS485. Gauges shall be similar to Weschler

Instruments Model BG-281TC. Provide custom scales showing the ranges shown below and showing the units of measure indicated.

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Required Gauges

Parameter Units Range Green

Range

Yellow

Range

Red

Range

Main (Inlet)

Steam Pressure psig 0-1000 395-405 351-394

406-420

0-350

421-1000

Main (Inlet)

Steam Temp o F 50-750 551-700 501-550

701-730

0-500

731-750

Steam Chest

Pressure psig 0-500 0-500

First Stage

Pressure psig 0-500 0-500

Extraction

Pressure psig 0-200 85-95 61-84

96-110

0-60

111-200

Main Oil Pump

Discharge psig 0-300 130-150 81-129

150-160

0-80

161-300

Exhaust, Wide

Range

In.Hg vac

& psig

30” Hg vac – 15 psig

25-30” Hg 20-24” Hg 19” Hg –

15 psig

Power Oil psig 0-300 130-145 122-129

146-160

0-121

161-300

Control Oil psig 0-300 110-125 91-109

126-140

0-90

141-300

Lube Oil psig 0-60 15-20 13-14

21-30

0-12

31-60

Seal Steam psig 0-30 3-5 1-2

6-10

11-30

Gland Seal

Condenser

In H2O vac & psig

40” H2O vac – 15 psig

6-18” H2O 40-18”

H2O &

6” H2O vac-15 psig

Cooling Water

Header psig 0-30 9-20 21-30 0-9

>30

Condensate Pump

Discharge psig 0-60 20-35 36-60

Hotwell Temp o F 50-250 50-90 91-105 106-250

Provide pressure transducers for all pressure gauges and temperature transmitters for all temperature gauges.

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Provide a temperature sensor in the hotwell for the hotwell temperature gauge.

F. Trip Defeat: Provide a trip defeat switch for the vibration monitor (includes selector switch labeled “Trip Defeat”, switch positions labeled ”Normal” and

“Defeat”).

G. Digital Tachometer: Provide a four-digit LED tachometer with 0.8-inch high numerals, or larger.

H. Provide a Main Steam Valve control consisting of a 3-position selector switch (labeled “Main Steam Valve” with positions labeled “Close”, “Stop” and “Open”), a red pilot light (labeled “open”) and a green pilot light (labeled

“close”).

I. Provide a Turbine Reset pushbutton labeled “TG #5 Reset”.

J. Provide a 2 position Idle / Synch Speed selector switch (labeled “Idle/Sych” and positions labeled “Idle” and “Synch”).

K. Provide a Trip & Throttle Valve test pushbutton labeled “Trip & throttle

Valve Test”. Include three associated pilot lights – red (labeled “run”), green

(labeled “closed”) and amber (labeled “test”).

L. Provide Gland Seal Exhauster controls (labeled “Gland Seal Exhauster”) consisting of a red pilot light (labeled “run”), a green pilot light (labeled

“off”), a black pushbutton (labeled “run”) and a red pushbutton (labeled

“off”).

M. Extraction Non-Return Valve: Provide indication labeled “Extraction Non-

Return Valve” with red and green pilot lights, labeled “open” and “closed”, respectively.

N. Condensate Pump A: Provide a Hand-Off-Auto selector switch labeled

“Condensate Pump A” with red and green pilot lights labeled “Run” and

“Off”, respectively.

O. Condensate Pump B: Provide a Hand-Off-Auto selector switch labeled

“Condensate Pump B” with red and green pilot lights labeled “Run” and

“Off”, respectively.

P. Provide a 3-position selector switch labeled “Extraction Valve” with positions marked “Close”, “Auto” and “Open”. Provide red and green pilot lights labeled “Open” and “Closed”, respectively.

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Q. Provide a 2-position selector switch labeled “Oil Heater” with positions marked “Enable” and “Off”. Provide red and green pilot lights marked

“Run” and “Off”, respectively.

R. Provide a non-resettable totalizer labeled “Cond. Return to Cond. Hotwell”.

Meter shall show six digits and register in kilo-pounds.

S. West Oil Pump: Provide an H-O-A selector switch labeled “Main Oil Pump

AC (West)”. Provide red and green pilot lights labeled “Run” and “Off”, respectively.

T. Center Oil Pump: Provide an H-O-A selector switch labeled “Aux Oil Pump

AC (Center)”. Provide red and green pilot lights labeled “Run” and “Off”, respectively.

U. Emergency Oil Pump: Provide an H-O-A selector switch labeled

“Emergency Oil Pump DC”. Provide red and green pilot lights labeled

“Run” and “Off”, respectively.

V. Turning Gear: Provide a 2-position selector switch labeled “Turning Gear” with positions marked “Auto” and “Off”. Provide the following pilot lights:

red labeled “Engaged”, green labeled “Disengaged”, red labeled “Auto” and green labeled “Off”.

W. Oil Vapor Extraction Fan: Provide pushbutton control labeled “Oil Vapor

Extractor”. Provide a black pushbutton labeled “Run”, a red pushbutton labeled “Off”, a red pilot light labeled “Run” and a green pilot light labeled

“Off”.

X. Condensate Recirculation Control: Provide a 2-position selector switch labeled “Condensate Pump Recirc Valve” with positions marked “Auto” and

“Open”. Include red and green pilot lights marked “Open” and “Closed”, respectively.

Y. Drain Valves: Provide a 2-position selector switch labeled “Steam Drain

Valves” with positions marked “Auto” and “Open”. Include red and green pilot lights marked “Open” and “Closed”, respectively.

Z. Hour Meter: Provide a six digit, non-resettable hour totalizer labeled “TG-5

Hours”.

AA. Load Control: Provide a 2-position selector switch labeled “Manual / Load

Control” with positions labeled “Manual” and “GE Load Control”. Provide a red pilot light labeled “Manual Enabled”. Provide another rred pilot light labeled “Load Share Alarm” and below that in smaller font

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“1) Switch to 505 Manual

2) Press 505 Reset”.

Provide a green lighted pushbutton labeled “505 Reset”.

BB. Governor Trip Announcement “cheat sheet”: Retype the “Woodward 505E

Trip Announcements” list that is taped to the control panel below the governor. Print the retyped list on a self-adhesive white plastic sheet and neatly apply the list to the new panel face below the governor.

CC. Replace the existing annunciator panel. Each lighted window shall be approximately 3” x 3”. When an alarm condition is detected, the appropriate light shall illuminate and the alarm horn shall sound. When the alarm has been acknowledged, the horn will be silenced, but the light shall remain illuminated until the alarm condition has been corrected. Conveniently located adjacent to the annunciator panel, provide the following pushbutton controls: Flasher Test, Test, System Reset and Acknowledge. The new annunciator panel shall have the following alarms, plus 1 to 5 spare windows:

1. TG 5 Trip,

2. Stop Valve Trip,

3. Bearing Temp High Trip,

4. Oil Temp High

5. Oil Reservoir High/Low

6. Oil Pressure Low

7. Exhaust Vacuum Low

8. Exhaust Vacuum High

9. Hotwell Level High

10. Hotwell Level Low

11. Hotwell Level Low-Low

12. Condensate Pump Low Pressure Auto-Start

13. High Vibration

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14. Air Temp High

15. Generator Drain High

16. Ground Fault

17. North condensate Return Tank High Level

18. TG5 Basement Sump Level High-High

19. Sanitary Sump Level High-High

DD. Provide new panel with alarm horn and red flashing strobe light.

EE. Provide engraved laminated plastic labels for all controls, monitors and gauges. Labels shall have black letters on white backgrounds. Letters shall be a minimum of 3/8” high.

FF. Paint the front of the 10-inch sheet metal bracket on top of the control panel blue, to match the label above the Turbine 3 control panel. Paint “TURBINE

5” in 6-inch high white capital letters, centered in the blue stripe.

3.9 ACCEPTANCE TEST

A. After the work is complete, perform a load test on the turbine-generator.

Operate unit at 1.0 MW for one hour. Verify that steam seal system, turbine temperatures, vacuum and vibration/thrust remain in the normal range.

Increase load to 2.5 MW, 5 MW, 7.5 MW and 10 MW, allowing the system to stabilize at each load rate. The turbine throttle and load control system will be observed for proper operation during the load ramp test. Record vibration levels at full speed and no load, 1 MW, 2.5 MW, 5 MW, 7.5 MW and 10 MW.

B. Run the generator at 10 MW (or lesser load, if requested by the CH&PP management) for 24 hours, with varying extraction steam flows. To pass the test, the generator must operate without drift throughout the entire 24-hour period.

C. Subsequent to passing the first 24-hour test, turbine-generator #5 will be set as the “peaking” turbine – it will follow…