Attachment_J-1_-_SOW.docx

Flaming Gorge G2 Stator Winding Re-Wedge

Solicitation No. R15PS00764

Colorado River Storage Project, Utah

Flaming GorgeG1 Stator Winding Re-wedge

U.S. Department of the Interior SPECIFICATIONS Bureau of Reclamation

TABLE OF CONTENTS

DIVISION 1 - GENERAL REQUIREMENTS:

DIVISION 26 – ELECTRICAL:

26 30 00 Stator Winding Re-Wedge

DIVISION 52 – FIGURES AND TABLES:

52 00 00 Figures and Tables

END OF CONTENTS

Flaming Gorge G2 Stator Winding Re-wedge Solicitation No. R15PS00764

Table of Contents 00 01 10 - 1

SECTION 01 11 00 - SUMMARY OF WORK

GENERAL

1.01 REQUIREMENT

Performing a re-wedge of the Flaming Gorge G2 Stator.

The major components of the work include:

· Evaluate the condition of the existing wedge system, including materials, ripple springs and system design.

· Provide a written repair procedure.

· Perform a complete re-wedge of the generator to include removal of existing wedges and ripple springs, re-install/replace wedges and ripple springs and install new locking wedges

· Evaluate ripple spring compression after work is complete.

Optional performing a re-wedge of the Flaming Gorge G3 Stator

1.02 LOCATION

The work is located at the Flaming Gorge Power Plant, near Dutch John, Utah.

1.03 DEFINITIONS

A. Furnish: To supply products to the project site, including delivering ready for unloading and replacing damaged and rejected products.

B. Install: To put products in place in the work ready for the intended use, including unloading, unpacking, handling, storing, assembling, installing, erecting, placing, applying, anchoring, working, finishing, curing, protecting, cleaning, and similar operations.

C. Provide: To furnish and install products.

D. Indicated: Shown, noted, scheduled, specified, or drawn, somewhere in the contract documents.

E. Demonstrate: To show product performance or compliance in the presence of the Government Inspector.

Quality Assurance: Inspection and tests performed by the Government to ensure compliance with the terms of the contract.

Quality Control: Activities performed by the Contractor to ensure work conforms to contract requirements.

Contractor Quality Testing: Specified tests to be performed by the Contractor.

1. The Government may use the test results for Quality Assurance.

2. The Contractor may use the test results as part of Contractor quality control.

a. The Government anticipates that these tests will be part of the Contractor’s quality control program; however the tests do not relieve the Contractor of providing adequate quality control measures in accordance with the clause at FAR 52.246-12, Inspection of Construction.

When the specifications use a word or term defined in the Federal Acquisition Regulations (FAR), the definition of the word or term shall be in accordance with FAR sections in effect at the time the solicitation was issued.

1.04 ACRONYMS

The following acronyms apply these specifications:

1. CO: Contracting Officer

2. COR: Contracting Officer’s Representative

PRODUCTS

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EXECUTION

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END OF SECTION

Summary of Work 01 11 00-2

SECTION 01 14 10 - USE OF SITE

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Include in prices offered in the schedule for other items of work.

1.02 SUBMITTALS

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

B. RSN 01 14 10-1, Land use plan:

1. For each Contractor use site on Government land:

a. Show use location and extent of impact. Uses include but are not limited to the following:

1) Buildings and service areas including offices, shops, warehouses, storage areas, fuel and oil storage areas, and fabrication yards.

2) Parking areas, temporary roads, and haul routes.

3) First-aid and medical facilities.

b. Describe methods for removing temporary structures and facilities, cleanup, and rehabilitating site after completion of construction activities.

2. Submit revised drawings of changes in use of Government land made during design and erection stages or after use of Government land is in operation.

1.03 PROJECT CONDITIONS

A. Government land may be used for required construction facilities.

B. When private land is used for construction facilities or other construction purposes make necessary arrangements associated with use of private land.

C. Location, construction, operation, maintenance, and removal of construction facilities on Government land will be subject to approval of the Government Inspector.

D. Do not interfere with work of other contractors or the Government in vicinity, or with reservations made by the Government for use of such land.

PART 2 PRODUCTS

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PART 3 EXECUTION

Use of Site 01 14 10 -

SECTION 01 33 00 - SUBMITTALS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Include in prices offered in the schedule for other items of work or for work for which a submittal is required.

1.02 DEFINITIONS

A. Days: Calendar days.

B. Required Submittal Number (RSN): RSN identifies items to be submitted together as a complete submittal.

C. Submittal Types, as listed in Table 01 33 00A – List of Submittals:

1. A – Approval:

Government approval is required.

Approval submittals are considered to be “shop drawings.”

2. I – Informational:

2. Government approval is required.

Informational submittals are not considered to be “shop drawings.”

The Government may return an Informational submittal or ask for additional information when an Informational submittal does not comply with the specifications.

1.03 SUBMITTAL REQUIREMENTS

A. In case of conflict between requirements of this section and requirements included elsewhere in these specifications, requirements included elsewhere take precedence.

B. General:

1. Prepare in English.

2. Label with contract number and title, and RSN.

3. Measurement units: US Customary Units.

C. Drawings:

1. Minimum identification in title block:

a. Contract number and title.

b. Contractors or supplier's title and drawing number.

c. Date.

2. Allow space for review stamps.

3. Size: D size (22 inches by 34 inches) or smaller.

4. Draw to scale with neat lettering using drafting equipment or computer drafting equipment.

5. Final drawings:

a. AutoCAD® format (.dwg) or Drawing Transfer Format (.dxf) on CD-ROM disc.

b. Original D size (22 x 34 inch) plots.

c. Show as-built changes, including revision dates, made during installation.

D. Product Data:

1. Mark manufacturer's data for commercial products or equipment, such as catalog cut sheets.

a. Identify manufacturer's name, type, model, size, and characteristics.

b. Illustrate that product or equipment meets requirements of specifications.

c. Mark items to be furnished in a manner that will photocopy (no highlighter).

d. Strike out items that do not apply.

E. Certifications:

1. Submittals requiring certification by a registered professional: Signed and sealed by registered professional.

2. Manufacturer’s certifications: Signed by authorized representative of the manufacturer.

1.04 SUBMITTAL PROCEDURES

A. Submit only checked submittals. Submittals without evidence of Contractor's approval will be returned for resubmission.

B. Submit complete sets of required materials for each RSN as specified in "Submittals Required" column in Table 01 33 00A - List of Submittals. A complete set includes all listed items for RSNs with multiple parts.

C. Submit number of sets specified in "No. of sets to be sent to:" columns in Table 01 33 00A - List of Submittals.

D. Include the following information in transmittal letters:

1. Contract number and title.

2. RSN for each attached submittal.

3. Responsible code.

4. Number of sets for each RSN.

5. Identify submittal as initial or resubmittal.

E. More than one RSN may be submitted under a transmittal letter, provided the responsible code is the same.

1.05 REVIEW OF SUBMITTALS

A. Time Required:

1. Submittal review will require 14 days for review of each submittal or resubmittal, unless otherwise specified.

2. Time required for review of each submittal or resubmittal begins when complete sets of materials required for a particular RSN are received and extends through return mailing postmark date.

B. Time in Excess of Specified:

1. The Government may extend the contract completion date to allow additional time for completing work affected by excess review time.

a. The time extension will be to the extent that excess review time caused delay to the contract completion date.

b. The time extension will not exceed the time used in excess of the specified number of days for review of submittals or resubmittals.

c. Concurrent days of excess review time resulting from review of two or more separate submittals or resubmittals will be counted only once in extending the contract completion date.

2. No time extension will be allowed if the Contractor fails to make complete approval submittals in sequence and within time periods specified.

3. Adjustment for delay will be made only to the extent that:

a. Approval was required under the contract, and

b. Requests for approval were properly and timely submitted and were approved.

C. Return of Submittals:

1. One set of submittals required for approval will be returned either approved, approved subject to identified changes, or not approved.

2. Submittals not approved:

a. Revise and resubmit for approval.

b. Show changes and revisions with revision date.

c. Describe reasons for significant changes in transmittal letter.

d. Resubmit returned submittals within 14 days after receiving the comments, unless otherwise specified.

e. Requirements for initial submittals apply to resubmittals.

3. Do not change designs without approval of the Government after approval drawings, documentation, and technical data have been approved.

4. The Government will acknowledge Informational submittals.

a. Informational submittals will not be returned when they comply with the specifications.

b. Informational submittals that do not comply with the specifications may be returned for resubmittal or additional information may be requested.

1.06 TRANSMITTAL

A. Addresses for codes listed in Table 01 33 00A - List of Submittals:

Electrical Engineer, Flaming Gorge Field Division, Attn: FG-200, Bureau of Reclamation, 5995 Flaming Gorge Visitor Center, Dutch John, UT 84023.

Contracting Officer, Bureau of Reclamation, Attn: FG-120, Bureau of Reclamation, 5995 Flaming Gorge Visitor Center, Dutch John, UT 84023.

B. Send original transmittal letter with appropriate number of sets to office listed in “Responsible Code” column in Table 01 33 00A – List of Submittals.

C. Send copy of transmittal letter with appropriate number of sets to offices that are not the responsible code, but show “No. of sets to be sent to” in Table 01 33 00A – List of Submittals.

D. When “No. of sets to be sent to” is 0, send a copy of transmittal letter to that office.

PART 2 PRODUCTS

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PART 3 EXECUTION

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Table 01 33 00A - List of Submittals

Section Title

delivery time Type Respon -sible code No. of sets to be sent to: **

* A indicates approval submittal, and I indicates informational submittal.

** EE indicates Electrical Engineer, Flaming Gorge Field Division, and CO indicates Contracting Officer For mailing addresses see paragraph 1.06 in this section.

END OF SECTION

Submittals 01 33 00 - 5

SECTION 01 35 20 - SAFETY AND HEALTH

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Include in prices offered in the schedule for other items of work.

1.02 REFERENCES

A. Bureau of Reclamation (USBR)

1. USBR RSHS-2009 Reclamation Safety and Health Standards

a. Available on the Internet at:

http://www.usbr.gov/ssle/safety/RSHS/rshs.html

b. Hard copies available from:

The Government Printing Office Superintendent of Documents North Capitol and H St. N. W.

MS-SSMC - Room 566 Washington, D.C. 20401

(202) 512-1800 (Stock item GPO-024-003-00190-2)

1.03 SUBMITTALS

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

B. RSN 01 35 20-1, Safety program:

1. Written safety program in accordance with Section 3 of USBR RSHS.

C. RSN 01 35 20-2, Monthly accident summary report:

1. Form 7-2218 or other acceptable form in accordance with paragraph 3.8 of USBR RSHS.

1.04 PROJECT CONDITIONS

A. Comply with USBR RSHS.

B. Provide and maintain a work environment and procedures that will:

1. Safeguard the public and Government's personnel exposed to Contractor operations and activities.

2. Avoid interruptions of site operations and delays in project completion dates.

3. Control costs in contract performance.

C. Do not require persons employed in performance of this contract, including subcontracts, to work under conditions which are unsanitary, hazardous, or dangerous to the employee’s health or safety.

D. Maintain accurate record of and report to the Government the following occurrences during performance of this contract:

1. Death.

2. Occupational disease.

3. Traumatic injury to employees or the public.

4. Property damage in excess of $2,500.

PART 2 PRODUCTS

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PART 3 EXECUTION

Safety and Health 01 35 20 -

SECTION 01 42 10 – REFERENCE STANDARDS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Include in prices offered in the schedule for other items of work.

1.02 REFERENCES

A. Referenced editions of standard specifications, codes, and manuals form a part of this specification to the extent referenced.

B. These specifications take precedence when conflicting requirements occur between specifications and referenced standard.

1.03 AVAILABILITY

A. Code of Federal Regulation (CFR):

1. Available online, authorized by the National Archives and Records Administration (NARA) and the Government Printing Office (GPO), at www.gpoaccess.gov/cfr/index.html B. Federal Specifications, Standards, and Commercial Item Descriptions:

1. Copies of Federal Specifications, Standards, and Commercial Item Descriptions may be obtained from GSA Federal Supply Service, see the provision at FAR 52.211-1, "Availability of Specifications Listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions, FPMR Part 10129."

C. Bureau of Reclamation Documents:

1. Printed copies of Reclamation Safety and Health Standards (RSHS), stock number 024-003-00190-2, may be purchased from the Superintendent of Documents at the U.S. Government Printing Office, phone number (202) 512-1800. RSHS may be downloaded at http://www.usbr.gov/ssle/safety/RSHS/rshs.html

2. Bureau of Reclamation Standard Specifications are designated with an M-series number. Copies of these documents may be obtained from Bureau of Reclamation, Attn 8668170, PO Box 25007, Denver CO 80225-0007.

3. Bureau of Reclamation manuals and other publications including significant scientific, technical, and engineering works are available from the National Technical Information Service (NTIS). Information regarding availability and pricing may be obtained by contacting NTIS at the following address:

United States Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, Virginia 22161 Telephone: (703)487-4650 or 1-800-553-6847

4. Bureau of Reclamation was officially named Water and Power Resources Service for a short period. References to Water and Power Resources Service or any derivative form are synonymous with Bureau of Reclamation.

PART 2 PRODUCTS

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PART 3 EXECUTION

Reference Standards 01 42 10 -

SECTION 01 51 00 - TEMPORARY UTILITIES

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Include in prices offered in the schedule for other items of work.

REFERENCES

Institute of Electrical and Electronics Engineers (IEEE) IEEE C2-2012 National Electrical Safety Code (NESC) Bureau of Reclamation (USBR) USBR RSHS-2009 Reclamation Safety and Health Standards

TEMPORARY ELECTRICITY

Electric power will be available for construction purposes. This power will be available as single phase, 60 hertz, alternating current at approximately 120/240 volts, and 3 phase 480 volts.

No charge will be made to the Contractor for use of electricity.

COMPRESSED AIR

Compressed air in the powerplant will be available for construction purposes. Make arrangements with the CO for use of compressed air.

No charge will be made to the Contractor for use of compressed air.

TEMPORARY WATER

Water from the service water system will be available for construction purposes. Make arrangements with the CO for use of water.

Provide means of conveying water to points of use.

No charge will be made to the Contractor for use of water.

USE OF GOVERNMENT OWNED CRANE

A 100 ton bridge crane is available for use during the performance of the contract.

The government will provide the crane operator Government use of the crane will take priority over contractor use.

Request use of the crane from the COR 48 hours before scheduled use.

PART 2 PRODUCTS

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PART 3 EXECUTION

Temporary Utilities 01 51 00 -

SECTION 01 78 30 - PROJECT RECORD DOCUMENTS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Include in prices offered in the schedule for other items of work.

1.02 SUBMITTALS

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

B. RSN 01 78 30-1, Final As-built Drawings:

1. Certified marked sets.

1.03 AS-BUILT DRAWINGS

A. Maintain 2 sets of full-size prints of contract drawings marked to show accurate and complete records of as-built conditions. Keep drawings at the jobsite and mark as work progresses.

1. Mark and dimension to show variations between actual construction and that indicated or specified in contract documents.

a. Include existing items revealed during construction.

2. Mark to define construction actually provided where choice of materials or methods is permitted in specifications, or where variations in scope or character of methods are permitted in specifications, or where variations in scope or character of work from that of the original contract are authorized.

B. Use standard drafting practice to represent changes and include supplementary notes, legends, and details necessary to clearly portray as-built construction.

C. Mark as-built drawings in the following colors:

1. Red - Additions to original drawings.

2. Green - Deletions to original drawings.

3. Blue - Notations necessary for explanation of as-built markings.

D. Allow the Government to review the drawings at all times.

E. Upon completion of work, sign marked prints as certified correct.

PART 2 PRODUCTS

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PART 3 EXECUTION

Project Record Documents 01 78 30-2

SECTION 26 30 00 – STATOR WINDING RE-WEDGE

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

Cost:

1. Lump-sum price offered in the schedule. Include all costs of labor, equipment and materials required for G2 Stator Winding Re-Wedge.

2. Lump-sum price offered in the option schedule. Include all costs of labor, equipment and materials required for G3 Stator Winding Re-Wedge.

Exercise of Option: See Clause I.6, FAR 52.217-9 regarding the exercise of the option to re-wedge the generator 3 stator winding.

1.02 SUBMITTALS

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

1. RSN 01 26 30-1, Repair / Re-Wedge Proposal

1.03 REFERENCE STANDARDS

Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE C2-2012 National Electrical Safety Code (NESC) National Fire Protection Association (NFPA)

2. NFPA 70-2014 National Electrical Code (NEC)

1.04 GENERAL

A. A rotor-in visual inspection of Flaming Gorge Generator 1 (G1) performed on 09/13/2011 indicated a significant number of loose and migrating wedges at the top and bottom of the stator. This necessitated a complete re-wedge of G1 in 2012. As a consequence of this problem Flaming Gorge Field Division began closely monitoring wedge tightness in Generator 2 (G2) and Generator (G3). A rotor-in visual inspection of G2 performed on 03/16/2015 indicated a similar condition had developed. Further inspection of G3 indicated wedges are beginning to loosen and migrate.

B. During the week of October 9, 2011 the following information was gathered from G1 prior to the re-wedge

1. Only 89 of the total 198 slots were measured for ripple spring compression/deflection (45% of the total slots surveyed).

2. Of the 89 slots measured:

a. All 89 slots were found to be below 70% compression

b. 77 of the 89 slots were found to be at or below 50% compression

c. 21 of the 89 slots were found to be at or below 30% compression

d. 1 of the 89 slots was found to have a reading of 10% compression

3. 59 of the total 198 slots (30%) were found to have migrating wedges, some wedges moved upward, most moved downward.

a. Approximately 12 of the 59 slots with migrating (dropping) wedges were found to have the second or third wedge moving as well, not just end wedge movement.

4. Borescope and detailed visual inspections did not detect any damage to stator bar insulation.

A full re-wedge was deemed necessary to correct this condition The winding does not have any positive wedge retaining devices (e.g. locking wedges, epoxy soaked felt under the figure-8 ties, RTV silicone, etc.); thus, there is nothing to arrest possible wedge movement.

Target compression during winding installation (new winding) was approximately 80%.

a. Per the drawings, utilizing the existing ripple springs compressed to 80% exerts approximately 116 psi on the bars to solidly retain them in the slots.

4. The partial ripple spring compression measurements performed by Reclamation personnel on 10/12/2011 can be supplied to the Contractor upon request.

PART 2 PRODUCTS

2.01 MATERIALS AND EQUIPMENT

A. Conform to NFPA 70 and IEEE C2.

PART 3 EXECUTION

3.01 GENERAL

A. Perform a 100% re-wedge of the G2 stator. Inspection and re-wedge repairs shall include, but are not limited to, the following:

1. Prior to any work, the Contractor shall perform a site visit, which shall include:

a. A general visual inspection of the stator wedging system.

1) Notify Reclamation if any abnormal conditions exist relating to the stator wedging system other than indications of looseness.

b. Ripple spring compression measurements on all 198 slots (100%) prior to any disassembly and/or repair work.

1) Submit this data to Reclamation in Microsoft Excel format. These values will be compared with post re-wedge measurements.

c. A determination if the existing wedges, ripple springs, and top filler material may be re-used or if new replacement or supplementary materials are required or recommended.

d. A gathering of all necessary data and information to specify, procure, and install top and bottom locking wedges.

1) Refer to Figure 1 for the desired locking wedge example.

2) Note: Installing new locking sections will likely include modification or replacement of the wedges adjacent to the top and bottom end wedges. This should be considered during this stage of the work.

A determination if the re-wedge work can be performed with or without removal of existing Figure-8 ties (refer to Figure 2).

If the existing Figure-8 ties are to be disturbed the Contractor shall submit a justification and procedure for removal and re-installation of the ties.

Generating a list of additional materials, if any, which the Contractor will need to, procure in order to perform the re-wedge work (e.g. locking wedges, additional filler, etc.).

Coordinate site visit and re-wedge work with the COR:

Contact: Kasey Frandsen, Electrical Engineer, Flaming Gorge Dam, Dutch John, UT.

Phone: (435) 885-3233 E-mail: kfrandsen@usbr.gov The Contractor shall submit a repair/re-wedge proposal to the field office for review and approval prior to performing any work.

The repair proposal shall contain but is not limited to the following:

A written description of the proposed wedge removal and installation procedures or methods including list of tools used for this task.

A written proposal for applicable quality control procedure(s).

Parts/materials list.

Equipment list (typical tools etc.).

List of personnel.

Work schedule to include delivery or task completion timeframe Perform the stator winding re-wedge on all 198 slots, which shall include but is not limited to:

Removal of existing wedges and ripple springs.

Determining the additional amount of slot filler, if any, to add to return ripple spring compression to between 80% and 90%.

Re-install ripple springs and wedges.

Installation of new locking wedges.

Perform ripple spring compression measurements on all 198 slots after the work is complete.

All materials which will be permanently installed in the generator must be suitable and compatible for use in a rotating machine with Class F (155 °C) insulating materials.

Wedges, ripple spring, semi-conductive slot filler, and all other materials installed in the stator must be rated for use with Class F (155 °C) or higher temperatures.

If the government selects to exercise the option of re-wedging G3, perform the work in accordance to the requirements of 26.30.00.3.01.A

END OF SECTION

Stator Winding Re-Wedge 26 30 00 - 1

SECTION 52 00 00 – FIGURES AND TABLES

PART 4 GENERAL

4.01 LIST OF DRAWINGS

Figures and Tables listed in Table 52 00 00A are made a part of these specifications.

PRODUCTS

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EXECUTION

Not Used Table 52 00 00A – List of Figures and Tables

Figure 1 - Example of Desired Locking-Type Wedge – Locking tabs snap into the air vents then the gaps between the locking fingers are filled with an epoxy resin to prevent it from vibrating loose.

Figure-8 Ties Figure 2 - Photograph showing Figure-8 Ties and several migrating wedges.

Figure 3 - Flaming Gorge G1 View of stator Bore - Current status of unit (rotor removed) as of October 2011.

Figure 4 - Flaming Gorge G1 - Additional examples of wedge movement.

Wedge #82: 2014 2015

Wedge #101: 2014 2015

Wedge # 154: 2014 2015

Figure 5 - Flaming Gorge G2 - Examples of wedge movement.

Table 1 - Flaming Gorge G1, G2, and G3 Nameplate Ratings

Table 2 - Flaming Gorge G1, G2, and G3 Armature (Stator) Winding Information

Table 3 - Wedging Design Information

Spring Pressure (deformed to 80%)

Table 4 - Pertinent Drawings

Figures and Tables 52 00 00 - 8 image1.wmf image3.jpeg image4.jpeg image5.jpeg image6.jpeg image7.jpeg image8.jpeg image9.jpeg image10.jpeg image11.png image12.png image13.png image14.png image15.png image16.png image2.wmf