MTECRACK_Section_C_SOO___TRD_1.pdf

MTE U1 Crack Repair Solicitation: 140R4022R0006

SECTION C – DESCRIPTION/SPECIFICATIONS/STATEMENT OF WORK

C.1 Clauses Incorporated by Reference

None

C.2 Clauses Incorporated by Full Text

None

C.3 Other Requirements The requirements of this procurement consist of three components, a Statement of Objectives (SOO), Technical Requirements Document (TRD), and Specifications.

The SOO identifies the overarching performance requirements and objectives of this requirement and is located at Attachment J.1 Statement of Objectives.

The TRD identifies the high-level technical requirements of this requirement and is located at Attachment J.2 Technical Requirements Document.

The Specifications identify critical guide specifications that are mandatory for all Reclamation constructions projects and is located at Attachment J.3 Specifications.

In response to this solicitation, the offeror will submit a contractor developed statement of work, detailing specific processes and procedures that are consistent with the three aforementioned documents. The Contractor Statement of Work will be incorporated at award and attached as Attachment J.4 Contractor Statement of Work/Proposal.

END OF SECTION

dculley Highlight Contractor may be confused about whether a Statement of Work is required to be submitted with proposal as a supplement to the technical proposal or if the Section L requirements cover this requirement. Need to make sure our Instructions to Proposers are clear and consistent throughout these documents.

sstone Highlight Recommend adding language similar to "The contractor shall not simply restate the government's statement of objectives nor use vague language such as 'in accordance with standard practice.' The SOW shall be specific and clearly communicate the contractor's proposed actions.

Attachment J.1 Statement of Objectives

MTE U1 Crack Repair

1.0 Program Objectives:

1.1. Mt. Elbert Pumped Storage Powerplant consists of two vertical type pump-generators.

Unit 1 motor-generator was designed by Westinghouse Electric Corporation in 1970 and commissioned in 1981. The motor rating is 170,000 HP, and generator rating is 106 MW. The rotor is approximately 25 feet 10 inches in diameter and 6 feet 5 inches in height, weighs approximately 575,000 pounds, and rotates at 180 rpm.

1.2. Mt. Elbert Pump-Generating Unit 1 rotor spider consists of eight radial arms supporting the rotor rim assembly. Two of the eight arms (arms 2 and 6) have bolt-on extensions that facilitated shipping during the original installation. Arm 6 developed an unrepairable crack at the bolted arm extension. The cause of the crack was determined to be overstressing of arm due to increased rigidity of the arm structure with the bolted extensions, poor weld geometry and quality, and changes in unit operations from the original design intent. Arm 2 has similar indications of overstressing.

1.3. Address rotor deficiencies utilizing a solution to be proposed by the Contractor and approved by the Government to return the unit to safe and reliable operation.

2.0 Technical Objectives:

2.1. Primary objective: extend life of rotor spider by 50 years.

2.2. Solutions must:

• Eliminate the bolted arm extensions on arms 2 and 6.

• Be compatible with existing generator components.

2.3. General Work Requirements:

• Provide design and mechanical analysis (Finite Element Analysis, Stress Analysis, Fatigue Life Analysis) for potential rotor spider repair.

• Provide value engineering comparison of repair and replacement options.

• Provide design and components for rotor spider to rim key to establish proper rim shrink at unit overspeed.

• Perform dimensional inspection and non-destructive examination of rotor spider.

• Furnish all labor, equipment and materials required for rotor spider repair or replacement.

• Installation of approved repaired or new rotor spider.

• Perform unit balancing.

• Support operational testing to demonstrate successful repair.

3.0 Contract Objectives:

4.1. Allow the Contractor sufficient flexibility and latitude to develop a feasible and innovative solution that meets the Government’s objectives.

4.2. Provide latitude to adapt to contingencies resulting from site conditions, changing schedules, and general construction happenings.

4.3. Utilize Contractor’s design documentation, cost estimates, and project schedule to definitize the fabrication and installation scope of work.

4.0 Management Objectives:

4.1. Allow Contractor maximum latitude to design, engineer, fabricate, and install an innovative solution that meets the Government’s objectives.

4.2. Share accrued Government experience and knowledge through design and review processes.

4.3. Partner with the Contractor to establish cost-effective and practical means to manage schedule, performance, quality, and risk.

4.4. Coordinate both Government and Contractor onsite repair activities to minimize unit outage duration.

5.0 Proposal Requirements and Specifications:

5.1. See the Attachment labelled: “Technical Requirements Document – Mt. Elbert Unit 1 Cracked Rotor Spider Repair” for system specifications and Contractor Statement of Work (CSOW) requirements.

Attachment J.2

Technical Requirements Document (TRD)

Mt. Elbert Unit 1

Cracked Rotor Spider Repair

March 2023 Department of the Interior (DOI) Bureau of Reclamation (BOR)

Contents

Section I 3

1. Description of Requirements 3

1.1. Background 3

1.2. Location and Description 3

1.3. Information Available to Selected Contractor 3

1.4. Scope of Work 3

1.5. TRD Description and Requirements 4

Section II 5

2. Requirements 5

2.1. Contractor Statement of Work (CSOW): 5

2.2. General Work Requirements: 5

2.3. Rotor Spider Repair (All of 2.3. requires Original Technical

Narrative):

2.4. General Schedule Details 6

2.5. Required Submittals 6

2.6. Contractor Quality Control and Reporting 6

2.7. Performance Requirements 6

Section III 6

3. Government Furnished Property (GFP) 6

Section IV 7

4. General Information 7

4.1. Other Considerations 7

4.2. Safety 7

4.3. Proposed CLIN Structure and Payment Schedule 7

Section V 7

5. Terms Explained 7

Section I

1. Description of Requirements

1.1. Background

1.1.1. Mt. Elbert Pump-Generating Plant consists of two vertical type pump-generators.

This project is specific to Unit 1 manufactured by Westinghouse Electric Corporation.

Unit 1 rotor spider consists of eight radial arms supporting the rotor rim assembly. Two of the eight arms (arms 2 and 6) have bolt-on extensions that facilitated shipping during the original installation. Arm 6 developed an unrepairable crack at the bolted arm extension. The cause of the crack was determined to be overstressing of arm due to increased rigidity of the arm structure with the bolted extensions, poor weld geometry and quality, and changes in unit operations from the original design intent. Arm 2 has similar indications of overstressing and, therefore, also requires repair.

1.1.2. The project includes the design and installation of the generator rotor spider repair to return the unit to safe and reliable operation for 50 years.

1.2. Location and Description

1.2.1. Work is located at the Mt. Elbert Pumped Storage Powerplant approximately 20 miles south-southwest of Leadville, CO via Highway 24 (US 24) and Colorado Highway 82 (CO 82), 24 miles north-northwest of Buena Vista, CO via US 24 and CO 82, and 144 miles southwest of Denver International Airport via Interstate Highway 70 (I-70), US 24, and CO 82.

1.3. Information Available to Selected Contractor

1.3.1. Relevant drawings for this project are provided in Attachment 00 00 02 - Drawings.

1.3.2. Refer to Attachment 00 00 01 – Specifications for requirements and other project information.

1.4. Scope of Work

1.4.1. Prepare installation drawings, specifications, and other submittals for generator rotor spider repair as detailed in Attachment 00 00 01 – Specifications and 00 00 02 Drawings. Prepare final designs/approved designs before installation and receive concurrence from Government on the correction method to be used.

1.4.2. Work must conform with applicable Federal, State, and local codes and regulations, using whichever regulation or code is most stringent.

1.4.3. Provide warranty work if/when required through the warranty period(s).

sstone

Is this the same attachment mentioned above as 'Attachment J3 - Specifications' or a different specifications attachment? If the same, be consistent throughout every document; if different, consider renaming to eliminate confusion caused by two attachments labeled 'specifications' sstone

Keep the language consistent to avoid confusion and the resultant questions; recommend using "repair or replacement" or similar verbiage throughout.

1.5. TRD Description and Requirements

1.5.1. This TRD defines the requirements to repair the generator rotor spider. The objective of this contract is to obtain a complete and operable generator at the identified location prior to March 31, 2025, and meeting the milestone dates below:

1.5.1.1. Required installation of rotor repair complete by January 31, 2025.

1.5.1.2. Commissioning to be completed within 6 months after completion of rotor repair.

1.5.2. This TRD establishes the minimum work requirements for complete installation necessary to repair the rotor spider, related work requirements, and installation of the repair purchased in this contract.

1.5.3. All work performed and supplies purchased by the Contractor will comply with the instructions contained in this TRD. The Government shall not be held liable for reimbursement of any unauthorized work tasks.

1.5.4. The Contractor shall expend no unauthorized effort under this TRD for additional engineering design of the rotor repair beyond what is agreed to. All effort shall be in accordance with this TRD and its contents. Any identified engineering tasks not contained in this TRD will be brought to the attention of the Contracting Officer and the Technical Team within 24 hours of identification of the requirement.

1.5.5. The functional capabilities for which this repair is designed shall not be changed, modified, or altered without approval from the cognizant technical/engineering authority within the Government via a formal request for variation or deviation.

1.5.6. The disassembly, inspection, manufacture, test, and installation of components, parts, and equipment shall conform to the instructions in this TRD and all applicable technical directives listed in Section II.

1.5.7. Required installation, as specified in Section B of the Solicitation and subsequent contract, is clarified as shown follows:

1.5.7.1. Required Installation means rotor repairs are complete and rotor assembly is ready for turn-over to Government for installation of field poles and generator assembly.

1.5.7.2. Work Schedule subject to advance request and Government approval for interruption of service, as detailed in Attachment 00 00 01 - Specifications.

1.5.8. Contractor is allowed to complete required installation earlier than January 31, 2025, at no additional cost to the Government. Coordination with the Government is required for placement of the rotor assembly on and off the work pedestal, inspections, operational testing, adjustments, and commissioning.

Section II

2. Requirements

2.1. Contractor Statement of Work (CSOW):

2.1.1 Contractor shall prepare a CSOW for this requirement containing the required elements of Section L for provision WBR 1452.215-81 Proposal Instructions. The CSOW shall describe how the Contractor intends to comply with the Attachment J.1 Statement of Objectives (SOO), the requirements of this Attachment J.2 Technical Requirements Document (TRD), and all applicable specifications and requirements. The CSOW is the basis for the Government to decide if the proposal is technically acceptable and to identify the proposal which is most advantageous to the Government. At a minimum, the CSOW (Factors 1 through 4 of the Technical Proposal) shall be incorporated into the contract in Section J as a formal attachment.

2.1.2 The Government will consider alternate approaches and strategies including but not limited to alternate pricing strategies, Economic Price Adjustments (EPAs), scheduling, and contract terms and conditions. Any requested changes in strategies shall be clearly identified in the CSOW.

2.1.3 In developing the CSOW, the Contractor should consider the Government’s priorities to be Quality, Schedule, and Price (in that order).

2.2. General Work Requirements:

2.2.1. The general work requirements for this rotor spider repair effort may include, but are not limited, to the following: drawing preparation, specifications submittals, material submittals, repair work, testing and warranty work as detailed in Attachment 1 – 00 00 01 Specifications.

2.2.2. The Contractor is expected to provide all materials, equipment, personnel, labor, management, tools, specialized equipment (if applicable), and supervision to successfully repair the generator rotor spider. All work shall be in accordance with the applicable laws, regulations, and documents incorporated into the contractual document and advertised in this Request for Proposal.

2.3. Rotor Spider Repair (All of 2.3. requires Original Technical Narrative):

2.3.1. The repaired generator shall meet requirements detailed in Attachment – 00 00 01 -

Specifications.

2.3.2. The design and construction shall be complete and without error. Meaning, the final state of the system must be operable for its intended purpose.

dculley Sticky Note Make sure this statement of priorities is consistent with final Section M.

sstone Highlight consistent naming sstone Highlight consistent naming sstone

Recommend staying consistent throughout the documents, naming 'Attachment J3 - Specifications' here in addition to 'all applicable requirements'

2.3.3. All equipment shall comply with Federal, State, and local standards and regulations.

2.4. General Schedule Details

2.4.1. Refer to Attachment 00 00 01 – Specifications.

2.4.2. Deliveries and on-site work for individual items of work shall not commence until all necessary installation design submittals have been received and approved, and the COR gives the Contractor written notice to proceed with on-site work unless otherwise agreed to by the Government and is negotiable based on the circumstances of this project.

2.5. Required Submittals

2.5.1. Refer to Attachment 00 00 01 – Specifications

2.6. Contractor Quality Control and Reporting

2.6.1. Refer to Attachment 00 00 01 – Specifications.

2.7. Performance Requirements

2.7.1. Government representatives will monitor the schedule and review schedule reports furnished by the Contractor to determine how the Contractor is performing against the agreed upon schedule in the contract. The Contractor will be responsible for making required changes in processes and practices to ensure installation and schedule is managed effectively. The Government may independently conduct tests deemed appropriate to assure quality. The Government may use its own tests or gathered data to determine any quality level.

Section III

3. Government Furnished Property (GFP)

No Government property will be furnished under this contract.

Section IV

4. General Information

4.1. Other Considerations

sstone Highlight Consistent naming sstone Highlight Consistent naming sstone

Consistent naming

4.1.1. Access to the site will require coordination with the Government.

Materials may be delivered and staged on-site as directed by the on-site Government personnel. At least 24 hours’ notice is required for scheduling deliveries or other access to the site.

4.1.2. The Contractor shall conduct regular coordination meetings with Government personnel on a frequency agreed to by both the Contractor and the Government. The meeting frequency shall be discussed during the pre-work meeting and adjusted as needed throughout the project. The coordination meetings shall include representatives of all parties involved in the work, such as the Contractor, subcontractors, inspectors, etc.

4.2. Safety

4.2.1. Refer to Attachment 00 00 01 – Specifications.

4.3. Proposed CLIN Structure and Payment Schedule

4.3.1. Measurement of work for the purpose of progress payments will be based on the price schedule in Section B of the contract. Individual Contract Line Item Numbers (CLINs) will include costs relevant to each CLIN. Payment will be for the lump sum price, or percentage thereof based on progress, for each CLIN in the schedule.

4.3.2. To allow the Contractor sufficient flexibility and latitude to develop a feasible and innovative solution that meets the Government’s objectives.

Section V

5. Terms Explained

Cognizant Technical/Engineering Government Personnel: Point of Contact identified by the Contract and the Contracting Officer at time of contract award. Equivalent to a Contracting Officer Representative but not required for supplies.

Contract Line Item Number (CLIN): Contracts may identify the items or services to be acquired as separately identified line items. Line items may be further subdivided or stratified for administrative purposes (e.g., to provide for traceable accounting classification citations).

Contracting Officer (CO): means a person with the authority to enter into, administer, and/or terminate contracts and make related determinations and findings.

Component: Subsystem, assembly, subassembly or other major element of an end item.

sstone

Consistent naming sstone

This is an incomplete sentence; what is the intended communication?

Defect: Any nonconformance to specified requirements.

Estimated Delivery Date (EDD): Estimated date of asset delivery.

Government: Refers to the Bureau of Reclamation and its authorized representatives.

Government Furnished Property (GFP): Property in the possession of, or directly acquired by, the Government and subsequently furnished to the contractor for performance of a contract (see FAR part 45.101). For the purposes of this TRD, property includes materials, equipment, carcasses provided to the Contractor.

Quality Assurance (QA): Policies and procedures adopted by the Government to ensure that supplies and services acquired under Government contracts conform to the contract’s quality requirements.

Support Equipment: Tooling or equipment utilized by personnel during the servicing, repair or manufacture of a component or an end item that does not become part of the component or end item.

Technical Data: All Government and Contractor drawings, specifications, standards, and all other technical publications necessary to restore an item to a serviceable condition.

Unserviceable: An item in a condition unfit for use but which can be restored to a serviceable condition after repair, rework, or remanufacture. This condition includes items requiring calibration, test, modification, assembly, or the addition of components.

Mt. Elbert Pumped Storage Powerplant Unit 1 Rotor Crack Repair

General Performance Requirements

01 81 05 - 1

SECTION 01 81 05

GENERAL PERFORMANCE REQUIREMENTS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Rotor Investigation and Design Recommendations:

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

2. Includes 45-percent design requirements.

B. Design Rotor Repair or Replacement:

1. Payment: Lump-sum price offered in Price Schedule B or Optional Price Schedule C as applicable.

C. Construct and Install Rotor Repair or Replacement:

1. Payment: Lump-sum price offered in Price Schedule B or Optional Price Schedule C as applicable.

D. Inspect Rotor Spider:

1. Payment: Lump-sum price offered in Price Schedule B or Optional Price Schedule C as applicable.

2. Price Schedule B includes pre-disassembly and post-reassembly dimensional inspection and NDE of existing rotor spider.

3. Optional Price Schedule C post-reassembly dimensional inspection and NDE of new rotor spider.

E. Over and Above Rotor Defect Repair:

1. Payment: Unit price offered in Price Schedule B.

2. Units: volume of measured excavation.

3. Includes excavation, repair, and NDE of rotor defects after weld excavation and after repair.

F. Commissioning:

1. Payment: Lump-sum price offered in Price Schedule B or Optional Price Schedule C as applicable.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME) sstone

45% is an unusual number; I've never seen it used in construction contracting. Is it common in the BoR? My experience is with 35%, 65% 95% and 100% but if customary BoR contractors use 45%, then no need to examine closer.

01 81 05 - 2

1. ASME BPVC-V-2017 Boiler and Pressure Vessel Code - Section V

- Nondestructive Testing

2. ASME BPVC-VIII Boiler and Pressure Vessel Code - Section VIII, Rules for Construction of Pressure Vessels, Division 1

3. ASME BPVC-VIII Boiler and Pressure Vessel Code - Section VIII, Rules for Construction of Pressure Vessels, Division 2

4. ASME BPVC-IX-2010 Boiler and Pressure Vessel Code – Section IX –Welding and Brazing Qualifications

B. American Society for Nondestructive Testing (ASNT)

1. ASNT SNT-TC-1A-2016 Personal Qualification and Certification in Nondestructive Testing

C. ASTM International

1. ASTM A609/A609M-12(2018) 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 E165-18 Liquid Penetrant Examination for General Industry

4. ASTM E709-15 Magnetic Particle Testing

5. ASTM E1742/E1742M-18 Radiographic Examination

D. American Welding Society (AWS)

1. AWS D1.1/D1.1M-10 Structural Welding Code – Steel

E. Bureau of Reclamation (USBR)

1. RSHS Reclamation Safety and Health Standards including revisions posted at https:// www.usbr.gov/safety/rshs/index.html

2. FIST 1-1-2018 Hazardous Energy Control Program

3. FIST 2-1-2016 Alignment of Vertical Shaft Hydro Units

4. FIST 2-2-2016 Manual Field Balancing Large Rotating Machinery

5. FIST 2-7-1994 Mechanical Overhaul Procedures for Hydroelectric Units

F. CEATI International (CEATI)

01 81 05 - 3

1. T122700-0381 Part II: Hydroelectric Turbine-Generator Units Guide for Erection Tolerances and Shaft System Alignment

G. Cahier Des Charge (CCH)

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

H. Code of Colorado Regulations (CCR)

1. 5 CCR 1001-10, Part B Regulation Number 8, Control of Hazardous Air Pollutants, Asbestos Control

2. 6 CCR 1007-2, Part 1, Section 5 Solid Waste Disposal Site and Facilities, Asbestos Waste Management

3. 6 CCR 1007-3 Part 261 Identification and Listing of Hazardous Waste

4. 6 CCR 1007-3 Part 261, App II Method 1311 Toxicity Characteristic Leaching Procedure (TCLP)

5. 6 CCR 1007-3 Part 262 Standards Applicable to Generators of Hazardous Waste

I. Steel Structures Painting Council (SSPC)

1. SSPC-SP10/NACE 2-07 Near-White Blast Cleaning

1.03 SUBMITTALS

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

B. Obtain Government acceptance prior to proceeding to next design phase:

1. Design submittals including re-submittals, shall contain all referenced documentation.

2. Include revised drawings and related documentation resulting from review of the submittal and additional comments in the re-submittal.

C. RSN 01 81 05-1, 45-Percent Design:

1. Preliminary Document List, to include, but not limited to:

a. Drawings.

b. Procedures.

c. Design Reports.

2. Specifications Table of Contents.

3. Detailed narrative description of rotor repair solution.

a. Include value engineering comparison of repair and replacement options.

sstone

To create a value engineering comparison of repair vs. replacement, will the contractor have to create a design for repair and a design for replacement? Are we really asking for two designs in order to have something to compare?

01 81 05 - 4

4. Explanation of objectives and factors influencing decisions.

5. Update proposal design submitted in response to the RFP if reviewed and approved by Government. Include output from design meetings and charrettes from time of award.

6. Commissioning Plan:

a. Project Requirements.

b. Proof of Design Plan.

7. Drawings:

a. Preliminary rotor repair plans, sections, and details.

b. Rim support, lifting and handling.

8. Procedures:

a. Rim shrink and key removal and installation.

b. Rotor NDE inspection.

c. Rotor dimensional inspection.

9. Design Reports:

a. Detailed design analysis and reports.

b. Stress and fatigue life analysis.

c. Finite element analysis.

d. Rim shrink and key fit analysis.

10. Material Analysis: Existing rotor spider material analysis report.

11. Hazardous Materials Abatement Plan.

12. Coatings recommendations.

13. Preliminary O&M Recommendations.

D. RSN 01 81 05-2, 45-Percent Comment Response:

1. Respond to Governments comments on 45-Percent Design.

E. RSN 01 81 05-3, 90-Percent Design:

1. Refine 45-Percent Design.

2. Updated drawings, procedures, and design reports.

3. Updated Specifications in MS Word.

4. Specifications:

a. Coordinated with drawings.

b. Other details needed to construct project.

c. File format: MS Word.

01 81 05 - 5

5. Commissioning Plan:

a. Updated Project Requirements.

b. Updated Proof of Design Plan.

6. O&M Recommendations Updated.

7. Reconciled submittal table in Section 01 33 00 – Submittals:

a. Include “To”, “From”, and “Copy” columns.

1) Include builder to designer submittals and design-builder to Government submittals.

2) Proposed changes to required design and construction submittals.

b. Modify due date or delivery time column in submittal table.

1) Replace “per contractors proposed schedule” with approximate due dates tied to construction of applicable item.

2) Include a minimum of 28 days or Government Review.

F. RSN 01 81 05-4, 90-Percent Comment Response:

1. Respond to Governments comments on 90-Percent Design.

G. RSN 01 81 05-5, 100-Percent Design:

1. Drawings, procedures, and calculation reports sealed by a professional engineer.

2. Construction drawings, procedures, and specifications at level of detail needed to construct project.

a. List of equipment and materials and individual submittals and a submittals table.

b. Show construction details on drawings.

H. RSN 01 81 05-6, NDE Qualifications:

1. Records for personnel listed in Non-Destructive Examination Requirements.

I. RSN 01 81 05-7, Construction Progress Submittals:

1. Customary construction submittals to assure an audit path record. To include, but not limited to:

a. Quality control plans.

b. Inspection test plans.

c. Material certifications.

d. Product data sheets.

e. Bill of materials.

f. Welder qualifications and procedures.

01 81 05 - 6

g. NDE reports and inspector qualifications.

h. Completed hazardous waste manifests.

i. Bills of Lading from solid waste disposal facilities.

J. RSN 01 81 05-8 Rotor Inspection:

1. Results of inspection including as-found dimensional inspection report.

2. Recommendations for rotor repair.

K. RSN 01 81 05-9, Rotor Weld Repair Report:

1. Results of NDE after weld excavation and after defect repairs.

L. RSN 01 81 05-10, Asbestos Visual Inspection and Final Clearance:

1. Air clearance and wipe sampling results to verify abatement.

M. RSN 01 81 05-11, 100-Percent Construction:

1. Rotor balance report.

2. Proof of design report.

3. Final torque values.

4. As-left dimensional inspection report.

5. As-built drawings, procedures, and design reports.

1.04 DEFINITIONS

A. FEA: Finite Element Analysis.

B. HP: Horsepower.

C. KV-A: Kilo Volt Amperes.

D. MT: Magnetic Particle Examination.

E. NDE: Non-Destructive Examination.

F. PT: Dye-Penetrant Examination.

G. RPM: Revolutions per Minute.

H. RT: Radiographic Examination.

I. UT: Ultrasonic Examination.

J. VT: Visual Inspection.

01 81 05 - 7

K. Commercial Operation: Fully operating unit after successful completion of commissioning has occurred to validate continuous operation and successful completion of Proving Period.

L. Proving Period:

1. Continuous operation of the unit for 30 consecutive days.

2. Contractor is allocated 72 hours of total unit downtime, which is cumulative.

M. Unit Downtime: When unit operation is interrupted due to operational issues that may result in equipment damage and/or safety concerns.

1. Only operational issues as a result of equipment supplied under this contract are applicable to Unit Downtime.

2. In the event of an operational issue not related to equipment supplied under this contract, Proving Period is paused.

1.05 PROJECT INFORMATION

A. Operation:

1. Unit is a pump-generator. A static frequency converter provides incremental power:

a. Increases to motor to reach operational pumping speed.

b. To brake from generation to pumping to reduce turn-over time.

2. Units rotate at 180 rpm, counter-clockwise in pump mode and clockwise in generation mode, as viewed from above.

3. Runaway Speed: 270.5 rpm.

4. Generator Overspeed: Unknown.

B. Pump-Turbine:

1. Pump-Turbine Rotating Mass Inertia (watered): 5,500,000 pounds at one-foot radius.

2. Weight of Pump-Turbine rotating parts with turbine shaft: 199,000 pounds.

3. Hydraulic thrust carried by thrust bearing: 800,000 pounds.

C. Generator-Motor:

1. Original Manufacturer: Westinghouse Electric Corporation.

2. Type: Vertical.

3. Year Installed: 1981.

4. Motor Input: 170,000 HP.

5. Generator Output: 105,263 KV-A at 0.95 power factor.

01 81 05 - 8

6. Generator-Motor Rotating Mass Inertia: 67,700,000 pounds at one-foot radius.

7. Number of field poles and weight: 40 poles, 4,700 pounds each.

8. Weight of rotor assembly with generator shaft: 575,000 pounds.

9. Thrust Bearing Capacity including Hydraulic Thrust: Unknown.

D. Spider Arm Material Analysis

1. Contractor to validate Government’s material analysis results.

2. Mechanical Strengths:

a. Ultimate Tensile Strength: 52 ksi.

b. 0.2-percent Offset Yield Strength: 24 ksi.

3. Chemical Composition (Percent):

Al C Cr Cu Mn Mb Ni P Si S Sn <0.1 0.12 0.04 0.02 0.60 0.01 0.02 0.006 0.18 0.025 <0.01

1.06 CONSTRUCTION COORDINATION

A. Prior to Contractor Mobilization, Government will:

1. Remove rotor assembly from generator and place on work pedestal within powerhouse and remove field poles. Includes pre-outage operational tests, unit disassembly inspections/measurements, removal of bearings and brackets, and post-disassembly inspections/tests.

2. Notify COR 45 days prior to mobilizing on site.

3. Turbine and generator shaft will not be removed.

B. Coordinate Contractor on-site work with Government including inspections and testing.

C. After completion of rotor repair Government will install field poles, rotor in generator, brackets, bearings, and complete assembly of generator.

D. Government to perform unit alignment and commissioning with Contractor support.

1.07 TEAM REQUIREMENTS

A. Project Manager:

1. Coordinate design and construction.

2. Establish lines of communication and protocol.

3. Monitor and control Contractor’s responsibilities.

4. Design Role:

a. Integrate design and construction activities.

sstone

Is notification sufficient to secure access or must the contractor receive approval?

01 81 05 - 9

b. Integrate design and construction activities into baseline schedule.

c. Ensure constructability and economy of design.

d. Integrating shop and installation drawings into construction drawings.

B. Designers of Record:

1. Licensed professional engineer in the United States or Canada.

2. Principal Designer of Record:

a. Integrate design and construction submittals.

b. Design team point of contact during design. Ensure dialogue between participants including Government, contractor, subcontractors and suppliers.

c. Point of contact for design team. Respond to changes, clarifications or additional information from members of the design team to Government and contractors.

d. Ensure submittals to Government are coordinated, logical, and comprehensive.

3. Engineers of Record: Sign, seal, and date 100-percent design drawings, specifications, calculations, procedures, and technical reports as applicable per discipline.

C. Designer representative shall be on-site during construction.

1.08 DESIGN/PERFORMANCE REQUIREMENTS

A. Rotor Repair:

1. Design solution for repair of crack on rotor arm number 6 and elimination of rotor arm 2 and 6 arm extension flanges. Possible solutions:

a. Complete replacement of existing rotor spider arms 2 and 6, compatible with existing rim, brake ring and key assembly.

b. Partial replacement of existing rotor spider arms 2 and 6, compatible with existing rim, brake ring and key assembly.

c. New rotor spider design compatible with existing generator shaft, bearings and rim.

d. New rotor spider, rim and brake ring design compatible with existing generator shaft, bearings, stator core and field poles.

e. Alternative solution proposed by Contractor.

2. Design solutions not permitted: Welded or bolted repair keeping the existing arm extensions.

3. Design new rim stand and drive keys and provide installation work plan.

01 81 05 - 10

4. Prepare commissioning plan for testing and approval of designed solution.

5. Design Constraints for Generator Rotor Assembly Weight:

a. Weight or rotor repair design shall not exceed weight of existing generator rotor assembly. Rotor assembly includes, but not limited to, rotor spider, rim, key assemblies, brake ring, cover plates, and hardware.

b. Validate compliance by weighing and recording weight removed and replaced to complete rotor repair.

c. Acceptance tolerance: 5 percent of weight removed.

B. Rotor Inspection:

1. Establish procedures for:

a. 100-percent NDE of existing rotor spider prior to rotor repair, unless a new rotor spider is provided.

b. 100-percent NDE of existing rotor spider after rotor repair or of new rotor spider if provided.

c. Dimensional inspection of rotor assembly prior to and after rotor repairs.

C. Rim Shrink and Rim Key Fit Design Requirements:

1. Existing Rotor Spider:

a. Replace 8 rim key assemblies, to include, but not limited to: spring keys, side plates, shims, drive keys, and stand keys.

b. Maintain radial connection between rim and spider at 120-percent synchronous speed.

2. New Rotor Spider: Based on designer’s recommendations for adequate rim engagement at 120-percent synchronous speed.

D. Spider Arm Loading Design Requirements:

1. Rotor arm static load (vertical) at rim ledge is equally distributed across 8 arms.

Acceptable deviation between maximum and minimum recorded loads is 5 percent.

2. Rotor arm static load (radial) with full rim shrink is equally distributed across 8 arms. Acceptable deviation between maximum and minimum recorded loads is 5 percent.

E. Design using industry standard materials and efficient practices.

F. Use high quality, durable and easily maintainable materials.

G. Contractor shall be responsible for professional quality, code compliance, technical accuracy, and coordination of designs, drawings, and specifications.

H. Hazardous Materials:

01 81 05 - 11

1. Generator may contain asbestos.

2. Generator structure coating contains regulated metals.

a. Use shrouded mechanical equipment or chemical means to remove coatings prior to work to minimize dust generation.

3. Refer to Sections 51 02 82 – Hazardous Materials Survey and Analytical Results.

4. Remove, dispose, and transport hazardous materials in accordance with:

a. 5 CCR 1001-10, Part B.

b. 6 CCR 1007-2, Part 1, Section 5.

c. 6 CCR 1007-3 Part 261.

d. 6 CCR 1007-3 Part 262.

I. Mechanical and Fatigue Analysis:

1. Design life of 50 years.

2. FEA Analysis and Report of rotor assembly.

3. Analysis showing rigidity, deflection, and stresses of rotor assembly:

a. Maximum loads, maximum output, load rejection, short circuit, and dynamic braking loads with static frequency converter.

J. Engineering Design and Report:

1. Title page and index for each volume.

2. Table of Contents if more than one volume.

3. Identify source of loading conditions, supplementary sketches, graphs, formulae, and references.

4. Explain assumptions and conclusions.

5. Include names or initials of Designer, Checker, and Peer Reviewer and dates of calculations and checking on calculation sheets. No calculation shall be computed and checked by the same person.

6. List design references including Government design documents and industry standards.

K. Drawings, Procedures and Calculation Reports:

1. Refer to Section 01 33 00 - Submittals.

2. Sealed by applicable designer of record.

L. Specifications:

1. CSI Manual of Practice and Master Format.

2. First page sealed by applicable designer of record.

01 81 05 - 12

3. Provide files in MS Word.

M. 45, 90 and 100 Design Packages:

1. Government will comment on design packages to ensure compliance with contract requirements. Review comments are considered part of the design-build process and shall be incorporated at no additional cost to the Government.

2. Comments:

a. Government’s review will be for compliance with contract requirements.

b. Contractor Response to Government’s Comments:

1) Identify action taken with citation of location within the relevant document.

2) Provide reasons if Contractor does not intend to comply with the comment.

3) Flag comments considered outside design scope and notify Government in writing immediately.

3. Refer to Section 01 31 19 - Project Management and Coordination for design review meetings.

1.09 WELDING QUALIFICATION REQUIREMENTS

A. Requirements to be specified on design drawings and procedures. Qualification records to be provided prior to construction.

B. Welding design, procedures, and welding operators:

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

2. Welding of low stress part: ASME BPVC-IX or AWS D.1.1.

a. Low stress is defined as stress levels less than one-third of material yield strength.

1.10 NON-DESTRUCTIVE EXAMINATION REQUIREMENTS

A. Requirements to be specified on design drawings and procedures.

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

C. Non-Destructive Examination Personnel:

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

BPVC-V.

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

3. Qualification minimum for UT and RT:

01 81 05 - 13

a. Performed by Level II with more than 10 years’ experience in UT and RT.

b. Inspection report reviewed and signed by Level III.

D. 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 with ASTM E165 or ASME BPVC-V.

4. Acceptance Criteria for VT in accordance with ASTM A802, Level 1 for all surfaces, as approved by Government.

5. Acceptance criteria for MT and PT proposed by Contractor and approved by Government.

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

E. UT Testing:

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

2. Acceptance Criteria for UT testing in accordance ASTM A609, Quality Level 1, 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.

F. RT Testing:

1. RT Testing is not permitted within Government facilities.

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

CCH 70.

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

G. 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.

1.11 MECHANICAL EVALUATION REQUIREMENTS

A. General:

1. In accordance with ASME BPVC-VIII Division 1 and 2.

2. Appropriate design factors and adequate shock absorbing features shall be used throughout the designs and especially in design of all parts subject to stresses or shock including alternating and vibrating type stresses and shock.

3. Include shock absorbing features which prevent components from loosening.

01 81 05 - 14

4. Design parts for maximum loading conditions: static and dynamic.

5. Design other parts for most severe normal operating conditions including load rejection or short circuit at machine terminals.

B. Allowable stresses under normal operating conditions:

1. Allowable stress is the lesser of the resultants:

a. 𝑆𝑆𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 𝐷𝐷𝐷𝐷𝐷𝐷𝑖𝑖𝑔𝑔𝑔𝑔 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 ∗ 𝑆𝑆𝑌𝑌

b. 𝑆𝑆𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 𝐷𝐷𝐷𝐷𝐷𝐷𝑖𝑖𝑔𝑔𝑔𝑔 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 ∗ 𝑆𝑆𝑈𝑈𝑈𝑈𝑈𝑈

2. For component materials permitted by ASME BPVC-VIII or for materials conforming to specifications of ASTM corresponding to ASME BPVC-VIII specifications when approved, the stresses are not to exceed:

a. One-half of yield strength of the material.

b. Two-fifths of tensile strength of the material.

3. For materials conforming to other specifications, the stresses are not to exceed:

a. One-third of yield strength of the material.

b. One-fifth of tensile strength of the material.

4. Design factor on shear stresses:

a. Application of Maximum Shear Theory.

b. One-half of yield strength of the material.

C. Allowable stresses under abnormal conditions:

1. Stresses not to exceed two-thirds of yield strength, permitted for the following parts under conditions given:

a. For rotating parts of turbine at temporary overload outputs greater than maximum design horsepower output of the turbine.

b. For all affected parts of turbine and generator, when subjected to maximum allowed runaway speed, load rejection and maximum hydraulic thrust.

c. Initial pre-stress of bolts.

D. Evaluation Criterion

1. Acceptance stress levels:

Stress Condition Pm ≤ Sallow PL ≤ Sallow Pm + Pb ≤ Sallow PL + Pb + Q ≤ Sallow PL + Pb + Q + F ≤ Samplitude

01 81 05 - 15

1.12 FATIGUE ANALYSIS REQUIREMENTS

A. Application of maximum and minimum alternating stresses under operating conditions.

B. Cycles:

1. Number of start/stops per day: 2

2. Number of load rejections per year in pump mode: 4

3. Number of load rejections per year in generation mode: 4

4. Number of change overs from pump to generate mode per day: 1

5. Number of change overs from generate to pump mode per day: 1

6. Number of runaways per year: 1

PART 2 PRODUCTS

2.01 MATERIALS

A. Miscellaneous materials including, but not limited to, hardware less than one inch in diameter (bolts, studs, nuts, dowel pins), gaskets, replaceable seals, O-rings, and piping shall be replaced with materials of higher grade or quality.

B. Lead-free and asbestos-free materials only.

C. Materials provided to meet ASTM standards.

D. Balance weights: Similar metal to rotor spider to prevent galvanic corrosion.

2.02 TOOLS AND EQUIPMENT

A. All tools and equipment required to perform rotor repair.

PART 3 EXECUTION

3.01 ROTOR REPAIR

A. Rotor will be removed from generator, placed on rotor pedestal in powerplant and field poles removed by Government.

1. Government will perform pre-tear down measurements and testing before removing rotor and field poles.

2. Contractor may observe. Coordinate observation with COR.

3. Government will provide Contractor with pertinent data.

4. Government will reinstall field poles and install rotor assembly in generator after work on rotor assembly is complete.

sstone

Is equal or higher acceptable, or must every material item must be replaced with a higher-quality material?

01 81 05 - 16

B. Reference Locations:

1. Reference to rotor center is the spigot surface on the rotor to shaft bolting flange.

2. Reference to rotor elevations is the horizontal surface on the rotor to shaft bolting flange.

3. Access to these surfaces is from top of rotor spider looking down into the rotor spider. Measurement devices and tooling shall be capable of reaching reference locations.

C. Rotor Asbestos Abatement. In accordance with approved plan.

D. Rotor Disassembly:

1. Perform pre-disassembly measurements, to include, but not limited to:

a. Brake ring flatness and levelness.

b. Rim roundness and concentricity to spider spigot.

c. Rim diameters, height, and elevation.

2. Remove brake ring.

3. Unshrink rotor rim and remove rim key components. Requires heating rim.

4. Remove rim. Permitted rim removal options:

a. Rim supported on powerplant floor and elevated above rim ledges.

b. Rim completely removed from rotor as one assembly.

c. Rim unstacked.

d. Alternative, as proposed by Contractor.

E. Perform rotor repair or replacement, as approved.

F. Manufacture: Rim keys.

G. Rotor Reassembly:

1. Meet or exceed tolerances given in USBR FIST 2-1 and CEATI Part II, whichever one is more stringent, as it pertains to rotor repair work.

2. Perform reassembly measurements, to include, but not limited to:

a. Brake ring flatness and levelness.

b. Rim roundness, verticality, and concentricity to spider spigot.

c. Rim diameters, height, and elevation.

3. Install rim.

4. Install rim key components. Requires heating rim.

5. Install brake ring with new hardware.

01 81 05 - 17

6. Document as-left torque values.

7. Document as-left measurements.

8. Any components destroyed or damaged in handling or during storage, as determined by the CO, shall be replaced or repaired in a manner approved by the CO, by and at the expense of the Contractor.

9. Repair paint damaged during reassembly in accordance with manufacturer’s recommendations.

3.02 NON-DESTRUCTIVE EXAMINATION

A. Prepare and perform NDE.

B. Preparations:

1. Erect containment structure during paint removal and abatement. Containment structure should provide environmental controls and air filtration.

2. Plug all holes and ports and protect all machined surfaces for cleaning and media blasting operations.

3. Remove coatings for NDE.

4. Abate and properly dispose of heavy metal coatings in accordance with local, state, and federal requirements.

C. VT Testing:

1. Perform 100 percent VT.

2. Components to be tested:

a. Rotor spider hub, flanges, plates, and arms

b. Existing and new welds

c. Rim ledges

d. Rim key pockets

D. MT and PT Testing:

1. Perform 100 percent MT or 100 percent PT.

2. Components to be tested:

a. Rotor spider hub, flanges, plates, and arms

b. Existing and new welds

c. Rim ledges

d. Rim key pockets

E. UT Testing:

1. Perform 100 percent UT.

sstone should or shall?

01 81 05 - 18

2. Components to be tested:

a. New rotor spider welds

b. Welds with defects identified with MT or PT.

F. Report:

1. Written and mapped description of results from NDE.

2. Digital photos.

3. Recommendations for repairs.

3.03 DIMENSIONAL INSPECTION

A. Measurements taken to nearest 0.001-inch or better using instruments with current calibrations.

B. Perform following dimensional inspections of rotor prior to disassembly and after reassembly. Including, but not limited to:

1. Brake Ring

a. Flatness, levelness and concentricity to spider spigot.

b. Shim dimensions and locations.

2. Rim

a. Roundness, elevation, verticality and concentricity to spider spigot.

3. Rim Keys

a. Shim dimensions

b. Key dimensions

4. Spider Rim Key Pockets

a. Verticality and flatness.

b. Pocket dimensions.

c. Pocket concentricity to spider spigot.

3.04 ROTOR DEFECT REPAIRS

A. Defect repairs on existing rotor welds and structure. Includes, but not limited to, excavation, NDE, welding, grinding, and materials and equipment necessary to complete defect repairs.

B. Recommend defect repairs for indications identified in rotor inspection.

C. Perform repair in accordance with AWS D1.1/D1.1M and ASME BPVC-IX.

D. Perform NDE:

dculley

Assume this NDE is specific to defects covered by "Over and Above" repair item as required by 3.04.D.

01 81 05 - 19

1. 100-percent VT: After excavation and repair.

2. 100-percent PT or MT: After excavation and repair.

3. 100-percent UT: After repair.

E. Report:

1. Written and mapped description of results from defect repairs.

2. Digital photos.

3.05 PAINTING

A. Preparations:

1. Erect containment structure during paint application. Containment structure should provide environmental controls and air filtration.

2. Plug all holes and ports and protect all machined surfaces for cleaning and coating operations.

B. Apply new coatings per designer’s recommendations to new material and disturbed areas.

3.06 COMMISSIONING

A. Assist and coordinate with Government during Commissioning.

B. Refer to Section 01 14 12, Work Restrictions.

C. Contractor Responsibility:

1. Install equipment and collect data, as needed.

2. Balance generating unit (turbine and generator coupled) in accordance with FIST 2-2.

a. Balance rotor to CEATI T122700-0381 or better:

1) Perform at rated speed and no excitation:

a) To be completed before operating with excitation or load.

2) Perform with excitation.

3) Perform with load.

b. Install balance weights to achieve tolerances as necessary.

1) If adequate, use existing balancing provisions on rotor spider arms.

Provide additional provisions if necessary.

2) Remove paint and touch-up paint as necessary to install weights.

c. Provide written report, evaluations, and recommendations.

3. Proof of Design:

sstone should or shall?

01 81 05 - 20

a. Provide all equipment and instrumentation. Coordinate with Government commissioning.

b. Rim Shrink and Key Fit:

1) Measure and record rim and spring key movement relative to spider at standstill, 25-percent speed, 50-percent speed, 75-percent speed, 100-percent speed and 120-percent speed during generating and pumping modes.

c. Rotor Spider Arm Loading:

1) Measure and record 8 spider arms radial and vertical loads at standstill, speed-no-load, 25-percent load, 50-percent load, 75-percent load, 100-percent load during generating and pumping modes.

D. Government Responsibility:

1. Perform operational, functional and performance tests on generating unit before placing into service.

2. Complete start-up and checkout procedures to ensure readiness of equipment and systems prior to the start of functional performance testing phase.

END OF SECTION

Section M - Evaluation Factors for Award