JDF Fish Pump Design Statement_final_2025.docx

JDA Fish Pumps Emergency Repair Project South Fish Ladder Units 1 and 2 Interim Bearing Repair

General:

The bearings on the fish turbine pumps are in a progressive failure state. Efforts have been implemented by Project personnel to provide a temporary repair which has a lifespan of 6 – 12 months. A more reliable repair is needed.

The scope of this project is to replace the bearings and gearbox, and repair the shaft and impeller for pump 2 at John Day Dam, with the option to repair elements of pump 1.

Statement of Work:

Rehabilitate John Day South fish turbine gearboxes and restore pumps to full operational capacity for 2, with the option to rehabilitate unit 1. This will include removing and replacing damaged bearings and the gearbox. The entire pump system will be realigned to meet manufacturer specs.

Prior work on fish pump No.3 included replacement of the lower pump shaft, true-up machining of the upper pump shaft, true-up machining of the upper and lower bearing mounting flanges and spigot bores on the cover plate and diffuser, and true-up machining of the diffuser extension cone. The propeller itself had its blade tips built up with weld and re-machined a proper clearance (nominally 1/8" radial clearance) to the pit liner. In addition, the propeller center bores were true-up machined for proper fit (0.004-0.006" clearance) to the new lower shaft. The upper and lower bearings were fitted with greaseless bearing liners and the shafts existing stainless bearing journals were replaced with spares originally manufactured by Worthington Pump. work will be replicated for pump No.2 and possible pump No.1.

The work to be performed under this contract includes the following tasks:

1. Provision of the labor, plant, equipment, and materials to transport, disassemble, replace, reassemble, and test one to two fishwater pump right angle drive gearboxes from John Day Dam.

2. Provision of labor, equipment, and materials to replace the shafts, bearings, and bearing brackets on the pump.

a. Replacement of lower pump shaft

b. True-up machining of upper pump shaft.

c. True-up machining of upper and lower bearing mounting flanges and spigot bores on the cover plate and diffuser.

d. True-up machining of the diffuser extension cone.

e. The upper and lower bearings are to be fitted with greaseless bearing liners

f. The shafts existing stainless bearing journals shall be replaced.

3. Provide new Operation and Maintenance manuals, general layout drawings, for the replaced gearbox.

4. Provide gearbox lube system spare parts (one each complete).

5. The contract includes requirements for the following: Provide gear design calculations and gearbox detail drawings.

6. The work consists of off-site steel and composite fabrication as part of the gear-box rebuilds, on-site installation of mechanical components, including a rebuilt turbine gearbox to be furnished by the Government, on-site installation of new pump shaft, bearings and bearing brackets, and other items defined in the Contract Documents.

The general work sequence to accomplish the above contracted tasks is as follows:

1. Remove input shaft coupling guard.

2. Disconnect the input and output shaft of the gearbox.

3. Ensure pump shaft is supported while it’s disconnected from gearbox.

4. Remove all the oil lube piping from gearbox.

5. Tear down gearbox.

6. Replace the gearbox assembly

7. Replace input and output shaft bushings

8. Reconnect input and output shafts

9. Install coupling guard

10. Align pump system by aligning turbine with gearbox and aligning gearbox with pump. Alignment must be done to manufacturer specs.

11. Balance the entire system.

12. Perform a pre-test inspection and ensure gearbox meets all design requirements.

13. Perform final test prior to returning pump to project.

The general project path of work is as follows:

1. Submittals for new pump shafts, gear box, and bearings are submitted

2. New components are ordered after submittals are approved.

3. Contractor mobilizes on site.

4. Contractor removes Unit 2 Gearbox, shaft and bearings.

5. Contractor installs new shaft and bearings

6. Contractor installs new Unit 2 gearbox.

7. Contractor tests completed install.

8. Contractor demobilizes.

9. Repeat for Unit 1 if option items are awarded

Schedule – PRELIMINARY & PROJECTED This preliminary schedule will change however, it is anticipated that the Contractor will have the following work windows to shut down the Units to perform the on-site Work:

· Unit No. 2: 1 DEC 2026 – 26 AUG 2027

· Unit No. 1: 1 DEC 2027 – 25 AUG 2028