Att_3_DO1.pdf

SOLICITATION NO. R16PS00407

ATTACHMENT 3

DELIVERY ORDER #1

RECONDITION BEARINGS IDIQ

Hoover Dam, Arizona- Nevada Davis Dam, Arizona Parker Dam, California

U.S. Department of the Interior Bureau of Reclamation Lower Colorado Region Boulder City, Nevada

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SOLICITATION: R16PS00407

DELIVERY ORDER 1

UNIT N5 THRUST BEARING SHOES

Schedule 1

Delivery Order 1 Item No.

Description Quantity Unit of Issue

Unit Price Total Price

1.

Delivery Order No. 1 - Provide all materials, equipment, supervision, labor, and transportation to pickup, recondition, and deliver eight (8) vertical, solid, equalizing thrust bearings (shoes) ea

Total Number of Days

2. Delivery time from pick up of thrust bearings at

Hoover Dam to delivery of completed thrust bearings to Hoover Dam days

Evaluation Criteria for Delivery Order 1

1. Offeror will be one of the awardees for a base IDIQ contract.

2. Proposed delivery time Time will be considered from the date of pick up from Hoover Dam to return of completed thrust bearings to

Hoover Dam.

3. Price

In the evaluation of Delivery Order 1, Criteria 1 through 3 are in descending order of importance. Number 1 carries more importance in the evaluation than number 2. Number 2 carries more importance than Number 3.

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R16PS00407

UNIT N-5 RE-BABBITT AND MODIFY THRUST BEARING SHOES 4/13/2016

STATEMENT OF WORK

UNIT N-5 RE-BABBITT AND MODIFY THRUST BEARING SHOES

HOOVER DAM POWER PLANT

1. REQUIREMENT

1.1 The Contractor shall recondition (8) vertical, solid, equalizing thrust bearings (shoes) for the Hoover Dam N-5 generator (clockwise rotation). This will include the re-babbitt, tolerance restoration and modification for (8) 85.5” diameter thrust bearing shoes made by Kingsbury.

1.2 In addition to the thrust shoe bearing re-babbitt, the following work shall also be performed with this

Delivery Order:

1.2.1 Each thrust shoe shall be machined to accept resistance temperature detectors 75% from the leading edge of the bearing and distanced radially 75% from the inner diameter of the shoe.

1.2.2 Each thrust shoe shall be re-sleeved for the high pressure lift system to ensure proper seal and operation which will include new check valves that allow for pressure testing.

1.3 All work is to be completed and returned to Hoover Dam by October 14, 2016.

2. SHIPPING

2.1 Shipping will be provided by the Contractor. The shoes will be boxed by Hoover personnel for pick-up by the Contractor. The shoes will be boxed as follows: four (4) boxes each with two (2) shoes per box. All thrust shoes are packaged and ready for pick up. The cost of transporting the bearing assembly to and from the Hoover Dam Central Warehouse shall be included in the unit price offered.

After work is completed and prior to shipping, all shoes and exposed metal services shall be protected from long term weather by preparing them with Cosmoline or equal.

2.2 The contractor shall provide all shipping FOB at destination:

Hoover Dam Central Warehouse

US Highway 93 / NV State Route 172 Boulder City, NV 89005

2.3 Hoover Dam Central Warehouse receiving hours are:

Monday – Friday (Pacific Time): 7:00 am – 3:30 pm

2.4 Hoover Dam shall be notified seventy-two (72) hours in advance of delivery so that rigging, crane/operator and a staging site are prepared for unloading. The contractor shall provide shipping racks to thrust bearing surfaces for each thrust bearing shoe. The contractor must include shoring for each thrust bearing shoe shipped. To notify, contact Jeff Ommen at 702-494-2288 and Randy Unverrich at 702-494-2513.

3. TECHNICAL POINT OF CONTACT

All technical issues shall be coordinated through:

Jeff Ommen jommen@usbr.gov

(702) 494-2288 or Manuel Contreras mcontreras@usbr.gov

(702) 494-2425

4. REFERENCE DRAWINGS

4.1 45-301-5478

4.2 45-301-6452

4.3 462086

5. SUBMITTAL REQUIREMENTS

5.1 Alloy Certification --- Babbitt certificate of analysis verifying material composition and compliance with ASTM B-23, Grade 2 must be submitted and approved prior to casting.

5.2 Ultrasonic Bond Test Results --- A detailed drawing must be submitted locating the position and area of all defects found in the bearing bond as well as any voids.

5.3 Liquid Penetrant Test Results--- A detailed drawing must be submitted locating the position and area of all defects found in the bearing bond.

5.4 Record Sheets- inspections and measurement data for the as-found and post rehabilitation shall be provided identifying any necessary modifications to the existing shoes.

5.5 Final Machining Results- shall be recorded and signed by a certified journeyman machinist or quality inspector and submitted prior to outgoing shipment.

5.6 Electronic copy of drawings for as built modified shoes

5.7 All required submittals shall be forwarded to Jeff Ommen and the Contracting Office.

6. TECHNICAL DESCRIPTION

6.1 MATERIALS

The Contractor shall use as a re-babbitting material, virgin babbitt type ASTM B-23, Grade 2, with the following composition: (89.0% tin, 7.50% antimony, 3.50% copper). Tin used for tinning shall be 99% pure and the use of reclaimed tin or babbitt will not be acceptable. Babbitt certification of analysis verifying material composition and compliance with ASTM B-23 Grade shall be submitted in accordance with Submittals section of this requirement.

6.2 BABBITT REMOVAL AND CLEANING

The Contractor shall remove all old babbitt from each bearing by means of machining and/or controlled heating procedures. Clean the bearing thoroughly for tinning and application of new babbitt.

Shot blasting with aluminum-oxide size-24 grit is acceptable for cleaning dovetail grooves. Care shall be taken to minimize thermal distortion of the bearing.

6.3 TINNING

After thorough removal of the old babbitt, the entire bonding surface for the babbitt shall be re-tinned.

Cast iron bearing shall be tinned with nickel. Stop-off shall be applied to areas not be tinned to prevent tinning compound from sticking.

6.4 RE-BABBITTING

The contractor shall temporarily plug oil passageways and temperature wells that are subject to babbitt infiltration prior to casting. The shoe and form shall be pre-heated. The thrust shoes shall be static cast in a continuous pour. Cold checks will not be acceptable.

6.5 MACHINING

6.5.1 The thrust shoes shall be milled flat, hand scraped and within tolerance and suitable for ultrasonic inspection. The inspection shall confirm the babbitt bond meets requirements stipulated in this specification.

6.5.2 The final machine of the babbitted surface shall be flat with the maximum low spot in the center of the shoe for the high pressure lift area. The high lift area shall not exceed .003”. Variation of thickness shall be as identified on the supplied drawings. The final machine finish of babbitt face shall be no smoother than 16-micro-inches upon completion of hand scraping the bearing.

6.5.3 All shoes must be hand scraped to show eight (8) to ten (10) contact points per square inch across 90% of the shoe area when checked against a calibrated surface plate. Shoes must be completely prepared for installation before the re-babbitt job is considered complete. Machining of oil grooving and scraping for high pressure lift is required as detailed on the referenced drawings.

6.6 INSPECTIONS & TESTS REQUIREMENTS

6.6.1 Before removal of old babbitt, determine if the cast steel shoe has porosity that may compromise the babbitt bond. Understanding that Hoover Dam uses a high pressure lift system at 1300 psi application of this test method shall be at the discretion of the OEM. Any failed test shall be documented and submitted to the government with recommended corrective actions for Engineering approval prior to retest.

6.6.2 After machining, the Contractor shall inspect the entire surface of the bearing for bonding to the cast iron shell using pulsed reflection ultrasonic inspection techniques in accordance with ASTM E114 (2001) from the babbitt side and 100% of the babbitted area shall be inspected. The UT procedure that is to be used shall be submitted.

6.6.3 The total area of un-bonded babbitt is not permitted to exceed (10) percent of the total babbitted surface, and no single un-bonded area is permitted to exceed a dimension of (1) square inch.

Lack of bond at any exposed bond line (s) is unacceptable. Less bond than the specified above shall require re-babbitting. The babbitt shall show no evidence of porosity by visual or ultrasonic inspection. A detailed, scaled drawing showing mapped bonding test results shall be submitted in accordance the submittals. Dove tail areas are exempt from total bond area requirement.

6.6.4 Liquid penetrant testing shall be implemented with a solvent-removable visible dye to define the babbitt/backing material bond at the edges. This inspection shall be in accordance with ASTM E165. Lack of bond indications greater than .125” in length shall be marked on the shoes and mapped and submitted with the test results.

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