Purchase Description.pdf

Purchase Description US Army Corp of Engineers, NWP District

NEW STATOR BARS PROCUREMENT FOR BONNEVILLE POWERHOUSE II

1. PROJECT BACKGROUND

Bonneville Powerhouse II has eight main unit generators. These units are rated at 80.5 MVA at

0.95 Power Factor and 13.8 kV. The original set of spare top bars has been exhausted, leaving only two remaining spare top bars both of which failed an AC high potential test prior to the Unit 18 repair. A reference drawing of both bottom and top bars is available.

2. SCOPE

This purchase description describes the procurement of stator bars which must match the construction and rating of the existing Bonneville Powerhouse II main unit stator bars, to be used as spares. The total quantity to be procured are 7 new top stator bars with the option to purchase up to three (3) additional bars. The new stator bars are to be delivered to Bonneville Lock and Dam no later than March 31, 2026 in accordance with Section 8 below, Shipment and Delivery.

3. WARRANTY

The warranty period for new bars is to be one (1) year beginning at the time of acceptance by the Government. The warranty shall cover repair and up to replacement of any supplied and properly stored stator bar which fails a strand continuity test, strand insulation test, or ground insulation dielectric test at any point within the warranty period, at no additional cost to the Government. Respond to the Government and provide a replacement plan within four (4) weeks of notification of the test failure and replace the warrantied bar within one (1) year of the test failure. Submit for approval the Stator Bar Warranty Details, to include duration of warranty coverage, contact information, and items covered by the warranty with submittal.

4. SUBMITTALS

Submit the following to the Government for approval. The Government will respond to each submittal within 30 days of receipt via email or RMS. Email submittals to roger.a.montavon@usace.army.mil

4.1. Stator Bar Manufacturing Facility: The name and address of the stator bar facility no later than 45 days prior to the start of manufacture.

4.2. Stator Bar Design Drawings: Include the following details in the drawings for the top bars no later than 45 days prior to the start of manufacture.

Cross-sectional view of stator bars in a stator slot.

Details of the stranding arrangement, including number of strands, dimensions, copper cross-sectional area, and insulation details, material and thickness.

Groundwall insulation materials and thickness.

Exterior dimensions of stator bars, bending radii, and slot and grading tape dimensions.

Design tolerance ranges for all dimensions.

4.3. Stator Bar Insulation System: A description of the stator bar insulation system, including processes and materials employed to meet specification requirements, and data sheets for materials used in the bar construction no later than 45 days prior to the start of manufacture.

4.4. Stator Bar Factory Test Procedures: Include all tests required by Section 7, Bar Factory Testing, no later than 45 days prior to the start of manufacture.

4.5. Stator Bar Factory Test Report: Include all test results covered by the submitted factory test procedures no later than 14 days following completion of the final bar and prior to shipment of the bars to site. Use each bar’s unique identification to report the test results.

4.6. Stator Bar Warranty Details: Include all details in accordance with Section 3, Warranty, no later than 45 days prior to the start of manufacture.

4.7. Stator Design Review Meeting Agenda: In accordance with Section 6, Stator Design Review Meeting, no later than 7 days prior to the date of the meeting.

5. STATOR BARS WINDING REQUIREMENTS

5.1. Winding Rating and Insulation Class: Supply stator bars suitable for use in a stator winding rated for continuous operation at 80.5 MVA at 13.8 kV +/- 5% and 0.95 PF. Provide stator bars with installation materials capable of operation at Class F winding temperature limits as defined in IEEE C50.12. Supplied bars are to be compatible with the existing stator winding to permit their use as spares without dimensional interference when installed in the same slot as and adjacent to the original stator bars. This includes ensuring alignment and compatibility with existing bar connections, brazing heads, series connection clips, and insulating caps.

5.2. Bar Design: Incorporate modern practice in design, material, and workmanship for the stator bars manufactured under this specification. Design bars to be the hard, multi-turn type with internal single turn type with Roebel transposition and minimized eddy current loss. Use annealed copper, free from splinters, flaws, rough spots, or short radius bends for the strands. Round all finished outside edges of each bar with a minimum radius of 1/16 inch. For the narrow side of the slot portion of each stator bar, provide a flat bearing surface of at least 3/8 inch. Do not cut or tailor bar leads for any particular slot; design each bar for use in any slot. If desired, both failed original spare top bars may be shipped to the Contractor’s facility to assist with design of the new spares at no cost to the government. In this case, Contractor to provide direction and shipping labels to the Government for proper shipment of the original spares. Additionally, the Contractor may travel to site to measure actual installed dimensions of the existing stator windings. The contractor will have access to the end winding area of the stator only on one generating unit. The contractor must provide the Government notice of this request at least 45 days in advance. In order to access this area, the contractor must complete Portland District’s Hazardous Energy Control Program (HECP) training. All costs for this training must be considered incidental to the work, and therefore, no additional payment will be made. Cost for the training is approximately $55 per individual. Training is provided by Vivid Learning Systems and is available online at http://contractor.vividlms.com/. Submit the training completion certification a minimum of seven days prior to the individual’s arrival at site.

Maintain training documentation on site, including the individual's name and date of training completion, in accordance with CENWP-OD-SAF-385-1.

a. Conductor Strand Insulation: Make strands continuous (splice free) within the entire length of each bar. Insulate strands with continuous filament glass, Dacron-glass fibers, or mica tape, bonded to the copper with a suitable bonding agent. Size and arrange conductor strands to minimize eddy and circulating current losses.

b. Ground Insulation: Provide ground insulation that consists of multiple overlapped layers of mica tapes applied continuously throughout the entire length of the bar.

Apply the same number of overlapped layers to achieve an equal thickness of ground insulation throughout the bar. Meet the requirements of NEMA FI 1, Table 5-4 or Table 5-6 for the mica tape. Use mica tapes constructed with a suitable backing material. Apply a suitable protective covering tape over the ground insulation mica tape.

c. Bar Consolidation: Bond the slot and end winding portions of the assembled strands and insulation into a rigid homogenous structure of controlled size using heat and pressure. Use strand bonding resins with properties and characteristics to prevent bond failure due to the mechanical, thermal, and chemical e ects associated with thermal cycling while operating within the Class F temperature limits for which the winding is to be designed.

d. Vacuum Pressure Impregnation (VPI): After drying treatments, completely fill the bar insulation with a solventless epoxy resin using a vacuum pressure impregnation process. After impregnation, cure the bar insulation system by the application of heat and pressure to the slot and end winding portions of the bars. Size slot portions to closely controlled dimensions and restrain end portions with suitable pressure devices to ensure a well-compacted insulation structure.

e. Finish and Partial Discharge Suppression Treatment: Treat slot portions of the stator bars, and a suitable distance beyond, with a semiconductive compound capable of giving positive electrical contact between the treated portions of the bar surface and the entire length of the core slot walls. Design this semiconductive treatment to eliminate surface discharge (corona) between the bar and slot surfaces and between top and bottom bar sides.

f. Graded Suppression Treatment: Apply a voltage grading semiconductive tape to the stator bar surface extending outward from the semiconductive treatment. Apply the voltage grading semiconductive tape to be of a length and resistivity to limit bar surface voltage gradients to levels well below corona onset levels under normal operating voltage stresses at normal operating temperatures.

g. Bar Test Record: Give each bar a unique identification.

6. STATOR DESIGN REVIEW MEETING

Contractor to work with COR to Schedule a meeting between the Government and the Contractor personnel to discuss the technical specifications, stator bar design and manufacturing, testing, warranty, and shipment. The meeting shall be virtual. Submit an agenda for the meeting per section

4.7 above.

7. BAR FACTORY TESTING

7.1. General Testing Requirements: Prior to shipment, subject equipment supplied under this contract to the manufacturer routine factory tests. Perform additional tests as specified in paragraphs 7.3 through 7.6. Do not ship completed bars until the submitted test report has been approved by the Government. Perform tests in accordance with the applicable requirements of IEEE C50.12 and IEEE 115, in addition to any other standards specified elsewhere within this PD. The waiver of Government witnessing of any test does not relieve the Contractor of the responsibility of complying with these specifications. Contractor to furnish all necessary test equipment, instrument transformers, temporary installations, and personnel. Ensure all test equipment is calibrated prior to performing the specified test or group of tests. Inform the COR of all final tests and measurements via the submitted factory test report.

7.2. Stator Bar Factory Test Procedures and Report: Submit the factory test procedure for approval to COR. Include an outline and description of the test methods and equipment employed in the factory tests, including all required test values, durations, and pass/fail criteria. In addition to contractor factory routine tests, perform the tests in paragraphs 7.3 through 7.6. Following the completion of the tests, submit the certified Stator Bar Factory Test Report for each test.

7.3. Strand Continuity Testing: Test the continuity of each strand prior to testing the strand insulation. Bars with discontinuities of any strand fail the strand continuity test and must be removed from the supplied spare set.

7.4. Strand Insulation Testing: Verify strand insulation by applying a minimum of 110 Vac rms between each strand and all other strands. Bars which do not hold this voltage fail the strand insulation test and must be removed from the supplied spare set.

7.5. Ground Insulation Dielectric Test: Subject the ground insulation of each stator bar to a withstand test of 40 kVac for one minute. Bars exhibiting visible corona under typical factory lighting of 100 ft-c fail the ground insulation dielectric test and must be removed from the production set.

7.6. Stator Bar Dimension Test: Submit for approval the method by which the stator bar dimensions will be verified. Verify dimensional compatibility of the stator bars in the stator core, including critical features such as ends of laminated iron, clamping fingers, surge rings, slot overhang shape, interference with adjacent coils, and spacing. Report all results and failures in the factory test report.

8. SHIPMENT AND DELIVERY

8.1. Bar Acceptance Criteria: Submit the shipment release request to the Government for approval. This request will be granted when the factory test report submittal is approved.

Upon receipt on site, each bar will be subjected to the tests of paragraphs 7.3 through 7.5 prior to final acceptance. Failures will result in rejection of the failed bar and the

Contractor will be responsible for repairing or replacing the damaged bars. Alternatively, the Government may entertain other remedies with no additional costs to the Government.

8.2. Packing and Shipping: The Contractor shall be responsible for packing and shipping the bars in a manner that will ensure undamaged and complete arrival to Bonneville Lock and Dam. Physical damage to the bars due to improper packing and shipping will result in rejection of the a ected bars and the Contractor will be responsible for repairing or replacing the damaged bars.

8.3. Equipment Delivery: All the new stator bars shall be delivered free on board (F.O.B.)

destination to Bonneville Lock and Dam no later than March 31, 2026. No shipments are allowed other than normal business hours of Monday through Thursday 7:00 a.m. – 4:00 pm., excluding US Federal holidays. All shipments shall be delivered to:

US Army Corps of Engineers Bonneville Lock and Dam I-84 Exit 40 Cascade Locks, OR 97014

9. REFERENCE DRAWING

Reference drawing #34D277522 Stator Bar Winding has been provided with this Purchase Description for the Contractor’s use in the design and manufacture of the new spare stator bars. No use of that drawing beyond this contracted work is authorized. The Contractor is responsible for verifying the contents of the drawing if it is used to inform the design of the new spare stator bars.

10. SECURITY – N/A

11. ATTACHMENTS

a. Final - SAF 385-1 HECP 20230223

b. drawing_W57780070646

12. Points of Contact (POC)

Delivery POC: Roger Montavon – Roger.A.Montavon@USACE.Army.Mil; and

Derek Williamson – Derek.J.Williamson@USACE.Army.Mil (Tech Lead)

Contracting O icer: Darrell Hutchens – Darrell.D.Hutchens@USACE.Army.Mil

Contract Specialist: Jaren Bowman – Jaren.L.Bowman@USACE.Army.Mil