Final_PWS_Solicitation.pdf

Continuation of 1449, Block 20, Schedule of Supplies/Services

PERFORMANCE WORK STATEMENT (PWS)

Bureau of Reclamation

Columbia Cascades Area Office Chandler Turbine and Pump Overhaul

1.0 BACKGROUND:

The United States Bureau of Reclamation’s Columbia Cascades Area Office has a need to overhaul a turbine and pump at its Chandler Pumping Plant, which is located at 47415 Old Inland Empire Hwy, Benton City, WA. The unit that is to be worked on consists of a James Leffel & Co, turbine, and a

Worthington Hydrocone, pump.

2.0 SCOPE:

Furnish labor, equipment, and materials to overhaul a James Leffel & Co, turbine, and a

Worthington Hydrocone pump. The overhaul will consist of repair work to the pump and modification of a turbine shaft, shaft sleave replacement, installation of turbine runner (new, provided by government) to turbine shaft, fabrication of wearing rings and pump impeller repair.

Additionally, there may be a need to refurbish the guide and thrust bearing. The Contractor shall be responsible for all tools, equipment, labor, and materials for the pickup, delivery, rebuild, machining, balancing, and testing of the turbine and pump components as specified in this document. The government will be responsible for the disassembly and installation of the turbine, pump, and their components.

3.0 References

All work shall be performed in accordance with applicable industry standards including, but not limited to:

American Society of Mechanical Engineers (ASME)

ASME BPVC-V-2004 Boiler and Pressure Vessel Code - Section V - Non-destructive testing

ASME BPVC-VIII-2007 Boiler and Pressure Vessel Code - Section VIII - Division 1, Rules for Construction of Pressure Vessels, UW-51 and UW-52

ASME BPVC-IX-2007 Boiler and Pressure Vessel Code - Section IX - Welding and

Brazing Qualifications

ASME B18.8.2-2000 Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins

ASTM International (ASTM)

ASTM B23-04 Standard Specification for White Metal Bearing Alloys

ASTM A36-08 Standard Specification for Carbon Structural Steel

American Welding Society (AWS)

AWS D.1.1-02 Standard Code for Arc Welding in Building Construction

Department of Defense (DOD)

DOD-STD-2183 (1991) Bond Testing, Babbitt-Lined Bearings

DOD-STD-2188 (1987) Babbitting of Bearings Shells

MIL-C-16173D (1993) Corrosion Preventive Compound, Solvent Cutback, Cold-Application

Society of Protective Coatings (SSPC)/NACE International (NACE)

SSPC-SP5/NACE 1-00 White Metal Blast Cleaning

SSPC-SP6/NACE 3-00 Commercial Blast Cleaning

SSPC-SP7/NACE 4-00 Brush-Off Blast Cleaning

4.0 DEFINITIONS

a. NDT: Non-Destructive Testing.

b. NDE: Non-Destructive Examination.

4.0 PERSONNEL QUALIFICATIONS

QUALIFICATION OF WELDERS

1. Welding procedures and welding operators:

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

b. Welding of less important parts: ASME BPVC-IX or AWS D.1.1.

2. Non-Destructive Examination personnel:

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

5.0 GOVERNMENT-FURNISHED EQUIPMENT (GFE) AND MATERIALS:

a. Impeller balancing mandrel for machining and balancing.

b. Runner balancing mandrel for machining and balancing.

c. Stainless-steel turbine runner.

d. Turbine shaft.

e. Ringfeder Rfn 7014 180 x 250 Locking Assembly

f. As-built drawings for specifications. (Will be available upon Award)

g. Impeller wear rings, stationary and rotating.

h. Turbine wear rings, stationary.

6.0 TASKS:

a. PUMP IMPELLER AND ASSOCIATED WEAR RINGS:

1. Rotating wear rings will be removed and installed by the contractor.

2. Sandblast impeller to remove ceramic coatings.

3. Weld up any areas showing erosion or thinning in the casting. This will require the contractor to perform a chemical analysis of the bronze so the proper welding procedure can be used. USBR will be given ownership of chemical analysis results in case of future repairs. Blend welded areas to maintain the contour. Welding procedure is to be reviewed and approved by USBR representative prior to start of welding. Allow up to 10 days for approval of welding procedure.

4. The ceramic coating shall be applied as two or more coats at a thickness of 10 mils minimum per coat as per manufacturer's instructions to a final thickness of 20 mils minimum and 40 mils maximum.

5. Final machine Reclamation supplied stationary rings.

6. Finished wearing ring dimensions are to be taken by the Contractor on finished and installed stationary rings, and dimensions are to be approved by a USBR representative. Machine rotating wearing rings to fit stationary rings with specified clearance. (.026" clearance total).

7. Final machine and install Reclamation supplied rotating wearing rings on pump impeller.

8. Perform balance of impeller.

9. Provided balancing procedure and results to Reclamation.

10. Rough machine a new set of stainless-steel wearing rings to replace the spare set.

Rough machining is considered adding approximately 0.150” to the outside diameter

(OD) of the rotating rings and to the inside diameter (ID) of the stationary ring’s dimensions for finish machining later.

11. The Reclamation provided set of wearing rings that are to be installed in this overhaul need to have the final machining completed to the required clearance prior to installation.

12. Ship the impeller, and balance arbor equipment (provided by government) to

Chandler Power Plant.

13. Government will be responsible for the removal and installation of the stationary wear rings to include the removal and installation of the packing sleeve if replacement is necessary.

b. TURBINE RUNNER, ASSOCIATED WEAR RINGS, AND TURBINE SHAFT:

1. Final machining on integrated runner, rotating wear rings.

2. Finished wearing ring dimensions are to be taken by the Contractor on finished and installed stationary rings, and dimensions are to be approved by a USBR representative. Machine integrated rotating wear rings to fit stationary wear rings with specified clearance.

3. Perform balance of turbine runner

4. Provided balancing procedure and results to Reclamation.

5. Machine alter the existing Unit 1 turbine shaft as required to convert it to a shaft locking type coupling and proper fit for a Ringfeder Rfn 7014 180 x 250 Locking

Assembly (supplied by the government) and to place the top of the machined and balanced runner (supplied by the government) at the proper elevation when coupled to the shaft. Government will leave the existing runner attached to the shaft when shipped to the contractor.

6. Match the elevation of the new runner to the existing runner.

7. Prepare the balance arbor equipment (provided by government), make a crate, and ship the items to Chandler Powerplant.

8. Assemble shaft, Ringfeder, nosecone, and nut, verifying both fit and elevation.

9. Ship the runner, shaft, Ringfeder, nosecone, balance arbor equipment (provided by government), and nut assembly to Chandler Power Plant (Also return of unused shaft locating key from the old shaft design).

10. Contractor will supply two stationary wearing rings to replace existing spare rings.

11. Remove installed shaft sleeve from turbine runner shaft.

12. Install new shaft sleeve on turbine runner shaft.

13. Manufacture 32 SAE 660 Bronze (or equivalent material) bushings for the wicket gate stems. The size of these bushings are approximately; 3 inch OD, 2.5 inch ID,

2.75 tall, with grease grooves. More details and manufacture drawings will be available upon Award.

14. Government will be responsible for the removal and installation of stationary wear rings.

c. BEARINGS:

1. All bearing inspections, testing and repairs or refurbishment will be done in accordance with Attachment 1 and as approved by Reclamation. The existing bearings shall be tested for bonding by the UT (ULTRASONIC TESTING) method to determine if they can be reused. If COR determines that bearings can be reused based on the findings of the UT testing, contractor may be authorized to machine finish bearings. Contractor will provide report of surface condition and a proposed recommendation as to how much material will need to be removed to achieve required surface finish per drawings. COR will determine if bonding of bearings is acceptable after receiving inspection report and bonding report.

2. Bearings will be inspected for condition and measured for dimension by USBR on site at time of delivery. Bearings will not be accepted prior to USBR final onsite inspection.

d. ADDITIONAL TASKS, SIZES, AND INFORMATION:

1. Conduct laser leveling of pump case. This work will be onsite and scheduled by the

COR as the pump is available and in ready condition for alignment.

2. Pump Size and Information

a. Approximately a 4-foot diameter, Frances type, bronze, pump impeller.

b. Stainless steel stationary wear rings with approximate OD of 40 inches and 35 inches.

c. Stainless steel rotating wear rings with approximate OD of 38 inches and 33 inches.

d. The government will remove the existing stationary wear rings and install the final machined wear rings.

e. Impeller Rotating Rings: Fabricated from Type 420 stainless steel, or similar stainless steel as approved by the COR with a Rockwell C scale hardness of 30 to

35 and machined to specifications.

f. Impeller Stationary Rings: Fabricated from Type 416 stainless steel with a

Rockwell C scale hardness of 40 to 45 and machined to specifications.

g. The impeller wearing rings consist of two rotating rings which include an upper ring and a lower ring, and two stationary rings which include an upper ring, the

Elbow Suction ring, and a lower ring, the Stuffing Box Head ring. There shall be a minimum of 0.040” between the rotating and stationary rings, the tolerances shall be +0/-0.003 for the outer diameter of the rotating rings, and +0.003/-0 for the inner diameter of the stationary rings.

h. Impeller welding media: AMPCO Trode 150 welding rod or wire.

i. Impeller ceramic coating: 3M Scotchkote Urethane Ceramic Lining FG 514.

j. Balancing Mandril: Approximate weight 800 lbs. The contractor shall be responsible for transportation of the mandrel to and from the Chandler Power and

Pumping Plant. Use mandrel to balance to 450 RPM right-hand (clockwise) rotation. Balancing weights shall be added or removed in such a manner that there will be no depressions or projections from finished surfaces.

k. Reclamation will remove and install the impeller packing sleeve if replacement is necessary.

l. If necessary, manufacture a new impeller packing sleeve from stainless steel as specified by Reclamation.

3. Turbine Size and Information

a. Approximately a 3.5-foot diameter, Frances type, stainless, turbine runner.

b. Built in, rotating wear rings.

c. The turbine shaft is approximately 7-foot long with and 8-in diameter.

d. The government will remove the existing stationary wear rings and install the final machined wear rings.

e. The turbine stationary wear rings are to be fabricated from a single piece rolled ring forging from to 410 stainless steel. These are the upper and lower wear rings and shall be made in accordance with Reclamation specifications and are to be 20 to 25 Rockwell C scale hardness. Rings will be rough machined with

0.150" of extra material added on the ID dimensions for later finish machining.

f. Machine the turbine runner shaft sleeve from stainless steel having a Brinell hardness of 250 to 300, an OD of 9.000", and an ID of 8.000" per Reclamation specifications.

7.0 DELIVERY, STORAGE, AND HANDLING (Contractor Requirements)

a. Take every precaution during loading, transportation, and unloading.

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

c. Approximate weight total weight of all components: 5000 lbs. total.

a. Components crated and packaged by the Contractor, will require Contractor to provide adequate packing boxes for shipping to prevent damage to components. Boxes to be retained by Reclamation for future storage after delivery.

e. Pickup and deliver the components to the location.

f. A forklift and operator will be available at the powerplant for loading and unloading the components onto and from the Contractor's common carrier. Request from the COR these services a minimum of 24-hours prior to pick-up and/or delivery.

g. Notify the COR at least five full working days in advance of final delivery to the destination.

I. The Government will store the components in accordance with the manufacturer's recommendations.

8.0 Extra Work and Deficient Conditions

If additional work is required due to unknown conditions identified after inspection and testing, or during repair, the Contractor shall notify the Government immediately. The Contractor shall assess the level of additional work needed and submit a quote with itemized detail. The Government will review the quote and, any approved additional work will be executed with a bilateral modification.

9.0 DELIVERABLES

ITEM

CONTRACTOR

REQUIREMENT

Deadline Date RECLAMATION

Impeller

Spare/New Runner

Removed Runner

Bearings (Pump Guide, Turbine

Guide and Thrust Shoes)

Turbine runner shaft

Pick-up items Available to

Contractor by Nov.

12, 2024

Impeller Report of findings Nov. 25, 2024 USBR to respond no later than Dec.1, 2024

Impeller Repaired and recoated as approved

Feb. 10, 2025 On site and USBR accepted NLT Feb. 12, Runner #1 Spare Scroll case and headcover will be available for wear ring measurements by contractor

Dec. 7, 2024

Runner #1 Spare/New

Needed dimensions for final machine

New Packing Sleeve

Installed, Installed on machined shaft, ready to be shipped

Jan. 15, 2025 On Site and USBR accepted NLT January

21, 2025

Wicket Gate Bushings Manufactured and approved

Jan. 15, 2025 On site and USBR accepted NLT Jan. 21, Runner #2 (removed Runner) Removed from shaft and prepared for shipment back to Chandler.

Jan. 15, 2025 On site and USBR accepted NLT Jan. 21, Bearings Inspected, Tested and a report of findings submitted

Dec. 12, 2024 USBR to respond no later than December

22, 2024

Bearings Completed repair as approved by USBR.

Apr. 1, 2025 On site and USBR accepted NLT April 1, Spare Wear Rings Completed repair as approved by USBR.

Apr. 1, 2025 On site and USBR accepted NLT April 1, All other parts Laser leveling Feb. 21, 2025

Delivered back to plant Apr. 01, 2025 On site and USBR accepted NLT April

01, 2025

10.0 Drawings:

USBR - 566-100-124

11.0 CONTRACTING OFFICER REPRESENTATIVE (COR)

A COR will be appointed by a separate letter. The COR will serve as the point of contact for communication with the contractor. All communication shall go through the COR and CO. The contractor shall coordinate scheduling of repairs with the COR.

12.0 SUBMITTALS

Please see provision 52.212-1 Instructions to Offerors—Commercial Products and Commercial

Services for a complete list of items required to be submitted with quotes. Failure to include submittals could result in rejection of quote.

13.0 PERFORMANCE REQUIREMENTS SUMMARY

Desired Outcome: Successfully overhaul turbine and pump to like-new, working condition

Task

No. Performance Requirement

Method of

Surveillance

Acceptable

Quality Level

Performance

Standards

Performance

Measurement

Services necessary to overhaul turbine and pump

COR

Successful testing and operation of turbine and pump;

contractor will provide all complete deliverables.

Fully Operation of Pump before

April 01, 2025

COR report that 100% of task has been achieved.