Sol_Attach_4.pdf

Solicitation NO. R15PS00272

GSU Transformers and Associated Equipment Replacements

Attachment J-4 Questions and Answers

Glen Canyon Power Plant Middle River Division – Glen Canyon Unit – Arizona – Utah

Colorado River Storage Project

Solicitation R15PS00272, Attachment J-4

Glen Canyon GSU Transformers and Associated Equipment Replacements

Questions and Answers

Question 1: There are four bid items for the Contract Document Management System. Should the cost of the software be divided across all four?

Answer 1: Yes

Question 2: There are separate Bid Items for the copper and steel for salvage credit. Drawings and Nameplates only provide total weight of core and coils. Does BOR know how much copper and steel is in each transformer?

Answer 2: No.

Question 3: 01 32 10, Construction Program. Section requires a Full-time, on site employee experienced in developing and maintaining construction schedules.” CPM schedules are only reviewed and submitted on a monthly basis. Is a full-time, on site employee really required?

Answer 3: It is not required that scheduling be the on-site employee’s only duty. The employee responsible for schedule may also have supervisory or support duties as well.

Question 4: 01 54 20, Use of Government Crane. Can the crane be used for transformer assembly and disassembly for removal?

Answer 4: No. The Government Crane is a bridge crane, and can only be used by the contractor for off-loading and on-loading the delivery truck and moving materials within the powerhouse.

The contractor must provide their own crane and crew for bus work and transformer assembly and disassembly.

Question 5: 02 82 20, Removal and Disposal of Asbestos Containing Materials. Section requires extensive submittals and subcontractor qualifications for asbestos that has not been identified in the project.

Answer 5: The government has done a number of asbestos surveys and has not found asbestos containing materials within the scope of work of this project. However not all material is accessible or has been tested. The contractor will be responsible for removing and disposing of asbestos material found during the project in compliance with the specification.

Question 6: 02 83 30, Removal and Disposal of Coatings Containing Hazardous Materials.

Section requires extensive submittals and subcontractor qualifications for lead paint that has not been identified although paint on oil containment has been identified as not containing lead.

Answer 6: Lead paint was used extensively during the construction of the power plant. The bottom coat of paint on the buswork and bus supports is known to be lead based. If the contractor elects to re-use the existing supports they will need to sand-blast and re-paint the supports. It should be noted that these supports may be too small for the larger bus.

Question 7: 09 26 20 Coatings. Section conflicts with Transformer painting requirements in 48 19 30.

Answer 7: The transformer section applies to work performed in the manufacturing facility. The coatings section applies to all other situations.

Question 8: 48 04 00, 3.03 4 requires old transformers stored on site for at least 30 days.

Where will they be stored and what temporary oil containment will be required for each transformer? With oil, an area at least 65’ X65’ will be required.

Answer 8: A storage area is available at the top of the access road (tunnel). We will allow the contractors to remove the oil on the plant site prior to transport up the tunnel. During storage they will need to keep the transformers filled with dry nitrogen at a positive pressure. The only oil containment that will be necessary will be for leakage of residual oil.

Question 9: 48 00 3.03 B requires the oil to be disposed of as PCB contaminated. It appears the transformers have been tested and test reports are available to determine the proper disposal requirements. Will BOR provide?

Answer 9: The transformer oil has been tested and is classified as non-PCB (less than 50 ppm), but bushing oil concentrations are unknown. Test results are provided as an attachment to this solicitation.

Question 10: 48 19 30, Power Transformers 1.06 F4 provides for an Interim (in-shipment) SFRA Tests (Optional), but there is no Bid Item for the option.

Answer 10: This is a required, in-transit, test to be performed at the contractors expense if shipping damage is suspected. The test can be required if any of the conditions exist:

• Visible damage

• Loss of tank pressure

• Excessive readings on the impact recorder.

• Reports of improper handling.

Question 11: 48 19 30, 2.12 A c section requires special lifting beam for pulling core and coil.

This is usually performed at a transformer repair facility and not in the field. What is the purpose of this lifting beam?

Answer 11: The beam will be retained by the government. The purpose is to allow the government to perform in-house repairs if necessary.

Questions 12: 48 19 30 2.12 A d. Are there any special requirements for the hydraulic jacks required?

Answer 12: The hydraulic jacks must lift the fully loaded transformer, with oil, to allow for turning the wheels when moving them on the rails. The lifting of the fully assembled and oiled transformer must be done safely and smoothly. The contractor must determine the appropriate requirements for the jacks to be used.

Question 13: 48 19 30 2.12 B section requires oil filled Bushing Stand. Does the stand require its own oil containment or will it be placed in a Government furnished containment?

Answer 13: The bushing stand will not require a separate containment system.

Question 14: 48 19 30 3.05 C 5 states that if the existing insulated conductors and conduit are not of sufficient length or are not suitable for reuse the contractor must replace. How do we determined at bid whether the cable has to be replaced and what are the lengths required? On other projects the BOR provided a junction box to terminate the transformer control cabinet to plant cabling.

Answer 14: The question refers to the cables and wires that are landed in the existing transformer control boxes. It is the contractor’s responsibility to interface the new equipment with the existing cables and wires. The method for making this interface is up to the contractor.

If the contractor determines the existing wiring is insufficient due to the number of conductors, ampacity, voltage rating, etc., it will be the contractor’s responsibility to install new cables. The new cables shall run from the transformers to the E1A through E7A junction boxes, located directly below the transformers on the 2nd level. The distance is less than 250 feet. If cable cannot be reused due to a deteriorated condition, it will be the government responsibility to replace.

Question 15: 48 19 32 3.05 section requires numerous oil samples be taken prior to installing.

Would the BOR accept Certifications for each tanker from the supplier? There are significant costs in holding tankers on site and limited storage for storage tanks.

Answer 15: No. There is sufficient room at the storage area for either holding tankers or placing temporary storage tanks for the oil.

Question 16: Will Reclamation accept a letter of credit in lieu of a surety bond?

Answer 16: Yes.

Question 17: What is the amount of the bonding that will be required? Will the bond be required to be maintained during the entire period of the contract?

Answer 17: Bonding is required for the construction components of solicitation – Schedules A- 2, B-2, C-2, and D-2. Performance and payment bond in the amount of each schedule will be required prior to beginning work on that schedule. The performance bond must be maintained for the duration of the warranty period, but the payment bond will be returned upon completion of the work on the schedule.

Question 18: Will you apply the Buy American act to the contract?

Answer 18: The Buy American Act applies to the supply components of the solicitation and the Buy American Act – Construction Materials Under Trade Agreements clause applies to the construction components of the solicitation.

Question 19: The specification requires MTW or THWN wiring internal to control cabinets and ancillary equipment. Manufacturers of this type equipment have shied away from this insulation because of the PVC within. Would SIS wiring be an acceptable alternative?

Answer 19: Wire insulation of comparable characteristics may be used but will require COTR acceptance.

Question 20: The specifications call for the use of Contract Document Management System.

Would the use of another Government Contract Document Management System be acceptable provided it fulfilled the salient and operating characteristics?

Answer 20:No.

Question 21: There is a requirement for short circuit testing on the spare 345 kV transformer.

Can this test be performed at the transformer manufacturing facility, or is the requirement for this to be performed by a third party?

Answer 21: Short-circuit testing by the manufacturer is acceptable if the manufacturer has a qualified testing facility.

Question 22: For outage coordination, are there minimal timelines for requesting clearances, e.g. 2 or 3 weeks? Are there other factors that will dictate outage scheduling, e.g. unit annual maintenance, other contract work?

Answer 22: Please submit the formal request at least two weeks prior to the outage date for outage longer than 1 week. The other considerations for scheduling outages will be the fall “High Flow Event” and other ongoing contracts such as turbine runner replacements and generator rebuilds. The government will commit to an outage window of Dec 1st through June 1st of the following year award of the contract, for four consecutive years.

Question 23: All nameplates on the existing units show a 110kV HV neutral winding BIL, but the specification requires 450 kV and 350 kV for the 345 and 230 respective units. Can you explain what is causing the increase in HV neutral BIL?

Answer 23: The specified neutral BIL is correct. The BIL is set to withstand full line voltage if the neutral connection is lost.

Question 24: The existing transformers appear to be sealed tank. Is there space for a conservator? Is sealed tank/N2 required? Is conservator required? If a conservator is required, in which segment (1, 2, 3, or 4) would BOR prefer it be located?

Answer 24: The conservator is required. We believe there is adequate space, however BOR cannot guarantee this as the transformers and conservators have not been designed. BOR does not have a location preference. It will be the contractor’s responsibility to provide a conservator design that fits in the space.

Question 25: Section 48 19 30, 2.15 C 3, Tank tests requires a 15 psi pressure test of the tank.

For an oil filled transformer tank, pressure near the bottom of the tank will approach 15 psi due to head pressure of the oil. Would this method be acceptable?

Answer 25: No. Testing must be performed in accordance with the specifications.

Question 26: Section 48 19 30, 2.15 C.4.n(2) specifies testing in accordance with IEEE standard C57.130, but subparagraph (a) stipulates that the dissolved combustible gasses show no more than a 10 ppm rise. This limitation is not in accordance with the identified standard.

Answer 26: The limit of a 10 ppm rise for dissolved combustible gasses remains the requirement. CO and CO2 are not counted as combustible gasses and are not included in the 10 ppm rise.

Question 27: Section 48 19 30, 2.02 A 3, Coil windings and conductors identifies round (disc) or helic design and construction. Will shellform-type windings be allowed? If yes, 2.13.B, core, would need to be amended to exclude shellform-type from the requirement B.2.

Answer 27: Yes, shell-form winding and core are acceptable.

Question 28: Per Specification, Section 48 19 22 GENERATOR ISOLATED PHASE BUS, Part 2.01 E.5, the bus enclosure shall be gasketed, in bolted sections. Per Specification, Section 48 19 34, TRANSFORMER ISOLATED PHASE BUS, Part 2.01 E.4, the bus enclosure shall be in gasketed, bolted halves. Can the Isolated Phase Bus be furnished in sections designed for the conductor and enclosure to be field welded, which is the current industry standard?

Answer 28: Yes.

Question 29: Per Specification Section 48 19 22, GENERATOR ISOLATED PHASE BUS, Part 2.01 F.2, there shall be factory welded bolting studs on the bus conductors. Per Specification, Section 48 19 34, TRANSFORMER ISOLATED PHASE BUS, Part 2.01 F.2, there shall be factory welded bolting studs on the bus conductors. Can these terminations be furnished with captive nuts or threaded SS backing plates and hardware, which is the current industry standard? This would include the use of spring loaded conical washers instead of split-lock washers as required for bolting assemblies containing aluminum conductors.

Answer 29: Yes.

Question 30: Per Specification Section 48 19 22, GENERATOR ISOLATED PHASE BUS, Part 1.04 C, a new design is required for the connection method to the existing bus and enclosure which connects to the existing SF6 circuit breakers. Per Specification Section 48 19 22, GENERATOR ISOLATED PHASE BUS, Part 3.01 B, the existing bus is to be removed up to the SF6 circuit breakers. Is there a specific point where the new Isolated Phase Bus is to connect to the existing bus at the SF6 circuit breakers, or is the new Isolated Phase Bus to connect directly to the SF6 circuit breakers?

Answer 30: The contractor is to install new Generator Iso-Phase Bus from the Generator to a point roughly half way between the PT Cubicle and the SF6 Generator Breaker. This scope includes replacing the Generator Terminal Bushings and all the equipment associated with the PT Cubicle. See drawing 557-D-456 for the general arrangement of the equipment in question.

The inserted drawing roughly depicts the connection point to the breaker bus.

Question 31 Specifications Section 48 19 30 POWER TRANSFORMERS, Part 2.06 A. 3, General Requirements, does not state the SCADA type of communications required. Which type of communication is required to be used for SCADA communications?

Answer 31: EthernetIP, Modbus and DNP3 at a minimum.

Question 32: Has the Bureau considered an alternative method for moving the transformer to the transformer platform (other than through the tunnel)?

Answer 32: The Bureau has considered many. Through the tunnel is the option we consider the best, but will consider other options proposed.

Question 33: Can removal work of transformers, Iso-bus, PT’s etc begin prior to the delivery of the new transformers?

Answer 33:.The new transformers need to have been delivered to the contractor’s local storage site before an outage can begin, or any removal work can begin.

Question 34: Does the government have all of the rail cutouts in storage for the transformer tracks? Will they be made available to the contractor?

Answer 34: Yes, the cutouts are at Glen Canyon and will be available for contractor use.

Question 35: What is the maximum load rating of the transformer deck?

Answer 35: 500 lbs/ft2

Question 36: Specification Section 48 19 30, 2.12, E. 2. (page 339) System Gas Analyzer, lists the Kelman MULTITRANS having the capability of measuring gasses in natural ester oils.

However the factory Technical Support Specialist, have stated that the Kelman is not capable of monitoring ester oil. Can Reclamation provide a manufacturer who meets all the salient features specified? Would the Calisto 2 be an acceptable alternate?

Answer 36: Reclamation personnel have contacted several manufacturers’ representatives who have verified that their devices would work with natural ester oils. It is our experience that the analysis of the dissolved gasses in natural ester oils is no different than the analysis of the dissolved gasses in mineral oil. Use of the Calisto 2 is an acceptable alternative.

Question 37: This is a 4 year project, with work being performed at 4 different times, and completing in 4 different stages. Some transformers will not be energized until much later than others. Will the warranty period for each location be staggered so as to start at the time that the individual portion of the project is completed?

Answer 37: Yes, the warranty for each set of transformers will begin when each set of transformers are fully tested, installed and accepted by Reclamation.

Question 38: Section 48 19 30, 2.06 A.5 states “All Microsoft Windows® compatible software available for use in data collection, storage and processing shall be included.” “All software available” is a broad requirement. Can the government be more specific about the software packages that are to be included in this section?

Answer 38: The requirement is that all software necessary to properly collect, save and analyze the data from any given device must be provided by the contractor.

Question 39: Section 31 30,CONTRACT DOCUMENT MANAGEMENT SYSTEM gives a great deal of specific detail about the capabilities of the software and management of it, but does not list any acceptable software packages or service providers for this. It is obvious that the government has a particular software package in mind to meet these requirements. Can the government provide the names of acceptable software packages, and/or acceptable suppliers of this service?

Answer 39: We are only interested in the output of the software and will not be using the software ourselves. So we do not have a particular software package in mind so long as we believe that it is appropriate for the job.

Question 40: Is there a conduit and cable schedule available for existing circuits and raceways for the transformers, PPT’s?

Answer 40: No, Glen Canyon does not have cable and conduit schedules.

Question 41: The warrantee requirements are not clear. In one place it calls for a 3 year warranty and in another it calls for 5 years. Similarly, in one location it indicates that the warranty starts when the transformer is tested and energized. In another it indicates that the warranty starts at “the completion of the work”, which could mean the entire project. Please clarify which is correct.

Answer 41: Clause I.6, FAR 52.246-18, applies to the supply schedules in the solicitation. It states “The Contractor warrants that for a period of three (3) years after the transformers commence operations or 5 years after acceptance of work, whichever comes first, all supplies furnished under this contract will be free from defects in material and workmanship and will conform with all requirements of this contract…”. Clause I.20, FAR 52.246-21, applies to the service (construction) schedules in the Solicitation. It states “This warranty shall continue for a period of 3 years from the date the transformers commence operations, or 5 years after final acceptance of the work. If the Government takes possession of any part of the work before final acceptance, the date of possession will replace the date of final acceptance in regard to the warranty period.” The intent is that the warranty for transformers commences with the date they are put in service, or ready to be put in service. The warranty extends to the earlier of 3 years from the date they are energized, or 5 years from when they are installed and ready to be energized. Installation and acceptance of each bank of transformers will constitute Government possession of part of the work before final acceptance, described in Clause I.20.

Question 42: Does the government have the Cad files on the existing equipment and system, or will the contractor have to develop all drawings from scratch?

Answer 42: Reclamation has Cad drawing for all wiring diagrams, one line, three line and schematics.

Question 43: Does the scope of the contract include recoating the entire surface of the deck or only resealing the joints? Are all joints on the deck to be resealed or only the joints between the powerhouse and the metal grating?

Answer 43: Resurfacing of the entire deck is not required, only the areas damaged by the contractor. Joints damages or broken during installation must be resealed.

Question 44: Are liquidated damages stated in 52.211-12 applicable to the entire project or are they accessed on a per transformer bank basis?

Answer 44: Liquidated damages are applicable on a per transformer bank, based upon the schedule agreed to between Reclamation and the successful offeror.

Question 45: FAR 52.246-21 requires a maintenance bond to be provided. Should we assume that the maintenance bond only applies to the 1 year warranty offered with construction items?

Small Businesses don’t have the financial capacity to back multi-year maintenance bond. If the maintenance bond applies to any supply CLINS, it must come from our manufacturer.

Answer 45: Maintenance bonds are required for all equipment for a period of 3 years after installation or 5 years after acceptance, whichever is first, as identified in clauses I.22, paragraph (k). Maintenance bonds may be provided by the manufacturer, but it is the responsibility of the prime contractor to arrange for and deliver the bonds to Reclamation.

Question 46: The solicitation requires company experience with projects of similar scope, complexity and magnitude. A small business will not have experience in the past 3 years with projects of this magnitude. If they did, they would no longer be a small business. We request magnitude be reduced or dropped.

Answer 46: I believe you are referring to the technical proposal instructions. Offerors are instructed to submit information on experience with projects of similar scope and complexity.

Offerors with demonstrated ability in the performance of projects which most closely match the current project will be rated more highly. Lack of experience in a project exactly matching the magnitude or complexity of the current project will not make us reject a proposal outright. You are encouraged to provide information which demonstrates your experience in carrying out complex projects.

Question 47: Can the government provide any further information on the existing generator bushings? Does the government know of a viable vendor for the replacement bushings?

Answer 47: The government has provided all the information available regarding the bushings.

The government is aware of several viable manufacturers but cannot recommend one at this time.

Question 48: Standard industry practice for procurements of large transformers include milestone payments.

Allowance for milestone payments would produce substantial instant contract savings. We request incorporation of the following: 10% upon approval of design and submittals, 20% upon receipt of steel & copper at factory, 20% upon tanking, 20% upon factory acceptance, 25% upon delivery, 5% upon site acceptance testing.

Answer 48: Milestone payments for the delivered price (85% of the total negotiated price) of the supply items can be arranged upon award of the contract. As noted above, 15% of the negotiated price will not be payable until completion of installation, including testing.

Question 48: Our concern is with the partial discharge testing requirement of the statement of work. It appears the testing requirement is much more stringent compared to the IEEE standard.

We request is that the PD requirements be relaxed to reflect the IEEE standard, similar to the previous specification.

Answer 48: There is a very specific reason that we are requiring this PD level for these transformers. When using Ester Insulating Fluids in large high voltage transformers previous failures and testing have shown that the main type of failure is from streamers at sharp points and tight bends. Streamers are a precursor to arcing, which then damages the transformers, often times catastrophically. At this time it is our belief that partial discharge is a precursor to streamers. Therefore, with this type of insulating fluid, it is critical that partial discharge be reduced to a minimum. The IEEE standard of 500 pC was developed as a response to many years of experience with mineral oil. However, the current requirement is for the maximum partial discharge be less than 100 pC.

We cannot emphasize enough that we do not wish the manufacturer to "crank out" their standard transformers, as we understand that this size and voltage of an ester fluid filled transformer is a completely new design to many manufacturers. We are requiring stringent tests for design testing purposes. These requirements were not meant to be standard manufacturing tests. We are expecting that all tests be completed and that there may be some extra costs in this regard.

This is a large, very important and critical project for the Reclamation and for the US power industry. It must be done with care.

Question 49: The specification requires a bubble test. Would Reclamation accept a dye penetrant test of the seams in lieu of the specified bubble test?

Answer 49: No. The manufacturer is allowed to do a dye penetrant test after doing the 24 hour pressure test and the bubble test.

Question 50: Are the anchorage system components to be galvanized or painted. They are listed in Tabulation No. 02 of the Coatings section to be painted, but Drawing 557-D-4617 says to provide vent holes for galvanizing.

Answer 50: Either is acceptable.

Question 51: What is the generator grounding impedance?

Answer 51: 300 Ohm (for all units).

Question 52: Section 01 35 30 1.03 Qualifications B states that the Safety Professional must hold a professional status in the safety field by virtue of education, training, certification and experience. Please clarify, what training, what certification, what experience will meet this requirement?

Answer 52: There is no universally accepted credential for safety personnel. Because of this Reclamation will accept varying combinations of education, training, experience and credentials to demonstrate the designated Safety Professional has the knowledge and ability to perform the required duties.

Question 53: Reference Section 48 19 29, what is the current rating of the existing neutral bus?

Answer 53: We were unable to determine the current rating of the neutral bus. However we were able to determine that the current rating of the transformer neutral bushings, to which the bus is attached, is rated at 400 Amps. The bus must be rated equal to the new neutral bushing, which will be calculated by the transformer manufacturer.

Question 54: Section 48 04 00 requires removal and disposal of cables and conduit from transformer control cabinet to transformer terminal box. Section 48 19 30 requires the reuse and re-terminate of insulated conductors and electrical conduits furnished and installed. It goes on to say that if the existing insulated conductors or electrical conduit are not of sufficient length or are not suitable for reuse then new insulated conductors and electrical conduit shall be furnished, installed and terminated. Insulated conductors and electrical conduits shall be in accordance with Sections 26 05 10 Conductors and Cables and 26 02 33 Electrical Conduit.

How do we determined at bid whether the cable has to be replaced and what are the lengths required? On other projects the Reclamation provided a junction box to terminate the transformer control cabinet to plant cabling. Please clarify what Reclamation is looking for throughout the question.

Answer 54: The question refers to the cables and wires that are landed in the existing transformer control boxes. It is the contractor’s responsibility to interface the new equipment with the existing cables and wires. The method for making this interface is up to the contractor.

If the contractor determines the existing wiring is insufficient due to the number of conductors, ampacity, voltage rating, etc., it will be the contractor’s responsibility to install new cables. The new cables shall run from the transformers to the E1A through E7A junction boxes, located directly below the transformers on the 2nd level. The distance is less than 250 feet. If cable cannot be reused due to a deteriorated condition, it will be the government responsibility to replace. If the cable has deteriorated to the point it cannot be re-used Reclamation will take responsibility to replace it. If new cable is needed for any other reason it is the offeror’s responsibility to install the new cable.

Question 55: Reference Section 48 19 30 specifies a Kelman, Multitrans in detail, to be placed on the wall behind B phase, this unit will monitor three transformers. Answer to a previous question states “Reclamation personnel have contacted several manufacturers’ representatives who have verified that their devices would work with natural ester oils. It is our experience that the analysis of the dissolved gasses in natural ester oils is no different than the analysis of the dissolved gasses in mineral oil. Use of the Calisto 2 is an acceptable alternative.”

Due to the answer of the Calisto 2 being acceptable, this brings up a couple questions

• This will take 3 Calisto units rather than 1 Kelman. Is that acceptable?

• Calisto only monitors a portion of the gases the Kelman does. Still acceptable?

• Mounting location? On the wall behind B phase will put the maximum amount of tubing for A and C phases beyond their perspective limits.

• Can the units be mounted on the transformers?

Answer 55: Any On-line DGA system will, of course, have to be installed per the manufacturer’s instructions and within the physical limits of the system. Mounting the DGA system on the transformer would be acceptable if the offeror provides documentation showing the addition vibration and heat does not adversely affect the performance and longevity of the DGA system. Reclamation has identified both the Kelman Multitrans and the Calisto 2 as acceptable.

Question 56: Can the Isolated Phase Bus be furnished in sections designed for the conductor and enclosure to be field welded, which is the current industry standard? If yes, will there be a future spec for field welding?

Answer 56: Yes, and yes.

Question 57: What is the single phase fault value? The given value in the spec would typically be for the three phase fault and since these would be single phase units, we would like to know what the single phase fault would be.

Answer 57: The contractor is required to replace two different section of iso-phase bus. The first is located between the generator and generator breaker. The single phase to ground fault current is 40 Amps. The second section of the iso-phase bus is the outdoor section connected to the transformers. The single phase to ground fault current for this section is 13,636 Amps.

The requirement is for the bus to be built for the three phase fault current listed in the statement of work. The information provided above does not change the short circuit withstand requirement identified in the statement of work.

Photographs of existing generator bushings.